GLOBAL MANPOWER DEVELOPMENT

R1600G - LOAD HAUL DUMP

OPERATOR’S STATION AND MONITORING SYSTEM
MODULE 1 - TEXT REFERENCE

SERV1867

R1600G - Load Haul Dump

Module 1 - Operator’s Station and Monitoring System
Text Reference

© 2008 Caterpillar Inc.

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OPERATOR’S STATION

Seat adjustments The operator’s seat can be adjusted to allow full pedal travel. The seat adjustments
should be made when the operator is sitting against the back of the seat. The seat
1. Lumbar support hand pump and backrest should be periodically readjusted to reduce fatigue.

2. Seat recline lever The seat is equipped with the following controls:

3. Suspension damping knob The lumbar support hand pump (1) increases support to the lower back. The valve
button on the hand pump is used to decrease support to the lower back.
4. Fore and aft lever
The seat recline lever (2) pulls up to move the back of the seat to the desired position.
5. Front seat cushion tilt lever The seat back will lock into position when the lever is released.

6. Rear seat cushion tilt lever The suspension damping knob (3) is turned to change the stiffness of the suspension
and is turned until the weight setting on the dial is the same as the operator’s weight.
The knob should not be turned past the maximum weight setting or past the minimum
weight setting.

The fore and aft lever (4) is pulled up and held to slide the seat forward or backward
to the desired position. Releasing the lever locks the seat into position.

The front seat cushion tilt lever (5) and rear seat cushion tilt lever (6) are pulled up to
adjust the seat cushions to the desired angle and height. The seat cushion locks into
position when the levers are released.
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Operator’s station The operator’s station in the R1600G Load Haul Dump machine includes the
Caterpillar Monitoring System. The Caterpillar Monitoring System consists of a gauge
1. Gauge display display (1), a speedometer / tachometer display (2), and a main display
module (3). Individual alert indicators for each machine system are located on the
2. Speedometer / tachometer main display module and on the separate indicator display (4).
display
The switch panel (5) contains switches for the front and rear lights, the lift
3. Main display module arm positioner, ride control (if equipped), operator mode scroll, remote control
(if equipped) and torque converter lockup.
4. Indicator display
The brake oil pressure gauges (6) (if equipped) show hydraulic pressure in the front
and rear braking circuits.
5.
The key start switch (7) is used to turn the electrical system on and to start the
6. Brake oil pressure gauges engine.
7. The parking brake control switch (8) is used to engage or release the parking brake.
The parking brake control is a push-pull type switch.
8.
The joystick (9) controls the lift arms (raise and lower) and bucket (dump and tilt
9. Joystick back) functions.
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Right hand console The front brake oil pressure gauge (1), if equipped, shows the hydraulic pressure in
the front braking circuit when the service brakes are fully applied. The rear brake oil
1. Front brake oil pressure gauge pressure gauge (2), if equipped, shows the hydraulic pressure in the rear braking
circuit when the service brakes are fully applied.
2. Rear brake oil pressure gauge
The diagnostic service port (3) allows for the connection of a laptop computer using
3. Diagnostic service port Cat ET software.

4. Service tool port The service tool port (4) allows the technician to connect a Caterpillar
4C-8195 Control Service Tool which provides diagnostic access to the
Caterpillar Monitoring System. This service tool allows the technician to scroll
5. through display modes on the digital display window and clear recorded
faults as required. A 257-8717 cable adapter must be used to connect the
4C-8195 Control Service Tool to the service tool port on the machine.

The autoshift control switch (5) activates the autoshift function.

NOTE:
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Indicator panel: The indicator panel includes seven indicators.

1. Action lamp
been registered by the Caterpillar Monitoring System. The automatic lubrication
indicator (2) (electric type), if equipped, will be on when the automatic lubrication
2. Automatic lubrication indicator system is in operation. The automatic lubrication indicator (2) (hydraulic type), if
equipped, will be on when there is a fault in the automatic lubrication system. This
3. Exhaust back pressure indicator indicator will be on for two seconds after the engine starts to alert the operator that

4. Primary steering indicator

grease.
5. Residual brake oil pressure The exhaust back pressure indicator (3), if equipped, indicates high exhaust back
indicator
must be cleaned. The primary steering indicator (4), if equipped, indicates a failure
6. Ride control indicator of the primary steering system. The secondary steering system (if equipped) should
be automatically activated.
7. Autodig indicator
The residual brake oil pressure indicator (5), if equipped, indicates that there is oil
8. Axle oil temperature/pressure pressure in the service brake section of the wheel brakes. The lamp will illuminate
indicator when the service brakes are applied. The lamp should go out when the brakes
are released. If this indicator stays on, the brakes are holding residual brake oil
pressure. The ride control indicator (6), if equipped, indicates the ride control system
is activated. The Autodig indicator (7), if equipped, indicates an Autodig cycle has
been initiated.
The axle oil temperature / pressure indicator (8) indicates excessive front or rear axle
oil temperature and that the front or rear axle oil pressure is low.
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Front console The front light switch (1) turns on the front lights and the tail light (if equipped) in the
upper position and turns the lights off in the lower position. The rear light switch (2)
1. turns on the rear lights in the upper position and turns the rear lights off in the lower
position.
2.
The remote control switch (3), (if equipped), activates the remote control system
3. when moved to the upper position.

4. The lift arm positioner switch (4) activates the lift arm positioner when moved to the
upper position. The lift arm positioner system returns the lift arm to a preset height
when the lift arm is lowered.
5.
The ride control switch (5) is a three-position switch. The three positions are AUTO,
6. OFF, and SERVICE. The ride control system dampens the bucket forces, which
causes a pitching motion as the machine travels over rough terrain.
7. Torque converter lockup control
The operator mode scroll switch (6), when moved to the upper position, scrolls
through the operator modes in the display window.

The torque converter lockup control switch (7) enables and disables the torque
converter lockup clutch.
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Overhead console The front window wiper and washer switch (1) turns on the front window wiper when

1. activated.

The side window wiper and washer switch (2) turns on the side window wiper when
2.
activated.

3. The rear window wiper and washer switch (3) turns on the rear window washer when

activated.
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HVAC controls The fan speed switch (1) operates the three-speed blower fan motor for heating and
air conditioning. The knob may be turned between the OFF position (left) and the
1. THIRD speed position (right).

2. Air conditioning knob The air conditioning control knob (2) is used to control the air conditioner temperature.
The knob may be turned between the MINIMUM position (left) and the MAXIMUM
3. Heating control knob position (right).

The heating control knob (3), if equipped, is used to control the heater temperature.
The knob may be turned between the MINIMUM position (right) and the MAXIMUM
position (left).

The air conditioning and heating system can perform four functions: heating, cooling,
pressurizing, and defogging.
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Right overhead console The idle timer control provides a timed period of idle (three minutes) before engine
shutdown when the key start switch is turned to the OFF position.
1. Idle timer on indicator

2.
engine will stop after three minutes.

The engine shutdown switch (2) allows the engine to be stopped immediately. Push
down on the engine shutdown switch to stop the engine.

To override the idle timer and stop the engine, turn the key start switch to the OFF
position and push the engine shutdown switch down.

NOTE: If the idle timer has been activated without starting the engine, it can
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Steering control Steering is controlled by the Steering Transmission Integrated Control (STIC) steering
control lever (1). The steering and transmission lock lever (2) is used to lock the
1. Steering control lever
lock lever is moved towards the STIC steering control lever (top view), the lock is
2. Steering and transmission lock
lever lock lever is moved away from the STIC steering control lever (bottom view), the
transmission will not shift into a speed until the transmission direction control switch
3. Transmission direction and
The transmission direction and control switch (3) selects the forward, neutral, and
reverse gears.
4.
The gear speed on STIC steering machines is selected by pushing the transmission
5. upshift switch (4) or the transmission downshift switch (5).
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Transmission shifting The autoshift control switch (1) controls manual and automatic transmission shifting.
In the manual mode the autoshift control switch is turned to the left. Pressing the
1. transmission upshift switch (2) causes the transmission to shift into the next highest
gear. Pressing the transmission downshift switch (3) causes the transmission to shift
2. into the next lowest gear.

3. In the automatic mode the operator can select the highest desired operating speed
from the options on the transmission autoshift control switch. The electronically
controlled transmission system selects the proper transmission gear according to
the ground speed of the machine.

The downshift switch is active in all gears. The downshift switch can cause transmission
downshifts at machine speeds that are higher than normal. Pressing and releasing
the downshift switch will cause a downshift of one gear. The downshift will only occur
if the machine speed and the engine speed will not result in an engine overspeed
condition. Pressing and holding the downshift switch will cause the transmission to
continue to downshift as the machine speed decreases. The transmission will remain
in the downshifted gear for three seconds after the downshift switch is released, then
automatic shifting is resumed.

To activate the autoshift function, the autoshift control switch is turned to a selected

selected gear. As the machine slows, the transmission will automatically downshift.
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The transmission neutralizer and service brake pedal (1) and service brake

1. Transmission neutralizer and by applying the service brake. The transmission neutralizer and service brake pedal
service brake pedal is also used to disengage the transmission, which permits higher engine speed for
better hydraulic response.
2. Service brake pedal

3. Throttle pedal increase or decrease engine speed.

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The joystick control lever (arrow) controls the lift arm and bucket functions. Pulling
the joystick back raises the lift arms and pushing the joystick forward lowers the lift
arms. The joystick is also used to control the bucket by moving the joystick to the left
for tilt back, and to the right for dump.
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CATERPILLAR MONITORING SYSTEM

Gauge Cluster Speedometer/ Main Display Action

Module Tachometer Module Module Lamp

°C kPa Miles Km rpm Liter Serv

12 Mph
Km/h 3f Code
X10

Action Alarm
Input
Components
Display Data Link

Cat Data Link

Power Train ECM Engine ECM

Input
Components Input
Components
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CATERPILLAR MONITORING SYSTEM

Monitors load haul dump

systems continuously monitors the load haul dump systems. The Caterpillar Monitoring
System components are: main display module, gauge cluster module, speedometer
/ tachometer module, an action lamp, an action alarm, and various switches and
sensors.

Main display module The “heart” of the system is the main display module where information is received,
via the CAT Data Link, from switches, sensors, and the ECMs. The main display
module processes the information, then activates various outputs.

Warning system outputs The Caterpillar Monitoring System includes four warning categories and provides
visual and audible warning system outputs. The visual outputs include the alert
indicators and the action lamp. The audible output is the action alarm.
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R1600G LOAD HAUL DUMP

CATERPILLAR MONITORING SYSTEM INPUTS AND OUTPUTS

Engine
ECM Operator Mode Scroll Switch
Cat Data Link
Main Display Module
- 10 Alert Indicalors
- Display Window
Power Train Hydraulic Oil
ECM Temperature Sensor Action Lamp
Fuel Level Sender
Main Display
Torque Converter Oil Module Action Alarm
Temperature Sensor
Display Gauge Cluster Module
Transmission Oil Pressure Sensor
Data Link

Brake Accumulator Oil Pressure Switch

(Alert Indicator) Speedometer / Tachometer
Module
Alternator "R" Terminal
+8 VDC
Harness Code Plug
Battery Voltage +9 VDC

Diagnostic
Connector
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Monitoring system inputs and This graphic shows the input and output components for the R1600G Load Haul
outputs Dump Caterpillar Monitoring System. Inputs are also received from other ECMs and
from various machine components.

Input components The various input components that send information directly to the main display
module are:

- operator mode scroll switch

- fuel level sender
- transmission oil pressure sensor
- hydraulic oil temperature sensor
- brake accumulator oil pressure switch (alert indicator)
- alternator “R” terminal
- harness code plug
- torque converter oil temperature sensor
- battery voltage

The Caterpillar Monitoring System also receives inputs from the Engine ECM and
the Power Train ECM over the CAT Data Link.
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Operator station console The main display module (1) contains the processing functions for the system, a
section that displays ten alert indicators (top half of module), and a bottom section
1. Main display module that displays a digital readout. The alert indicator section uses inputs from switches,
sensors, senders, and the CAT Data Link to alert the operator of machine conditions.
2. Speedometer / tachometer The digital display area provides a six digit readout that shows machine operational
module hours, engine speed, distance, and diagnostic information.

3. Gauge cluster module The speedometer / tachometer module (2) displays the engine rpm on the gauge,
the ground speed on the left lower digital display, and the transmission gear and
direction on the lower right digital display.
4.
The gauge cluster module (3) displays four of the changing machine conditions that
engineering determines are most often desired by the operator. The four gauges
used on the R1600G Load Haul Dump include the engine coolant temperature,
transmission oil temperature, hydraulic oil temperature, and fuel level.

The operator mode scroll switch (4) allows the operator or technician to select from
several modes of operation. Each mode selects the functions to be displayed on the
numeric readout window.
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Monitoring system indicators The Caterpillar Monitoring System provides four warning categories as previously
mentioned. Category 1 requires only operator awareness. Category 2 requires the
1. Parking brake alert indicator operation of the machine to be changed or a maintenance procedure to be performed.

2. Electrical system alert indicator category 3 requires immediate safe shutdown of the machine.

3. Maintenance required alert The following are category 1 warnings:

indicator
The parking brake alert indicator (1) indicates the parking brake is engaged and the
4.
indicator out when the parking brake is disengaged. If the electrical system alert indicator (2)

maintenance required alert indicator (3) is on constantly when the machine requires
5. Fuel level gauge maintenance and can be reset using a laptop computer with Cat ET or the Caterpillar
Monitoring System and the 4C-8195 Control Service Tool. Cat ET can also change

If the fuel level gauge (5) needle enters the red range, this indicates a low fuel level
(15 percent of the tank capacity). To avoid running out of fuel, the tank should be
refuelled within the hour.
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Monitoring system indicators In warning category 2, one of the following conditions will occur:

1. Action lamp -
-
2. Engine coolant temperature
gauge A change in machine operation is required to reduce excessive temperature in one
or more of the systems. The machine should be moved to a convenient place and
3. Transmission oil temperature parked and the cause of the alert indicator or the gauge should be investigated, and
gauge reported immediately.

4. Hydraulic oil temperature gauge The needle in the red range of the engine coolant temperature gauge (2) indicates
excessive engine coolant temperature. If the needle is in the red range of the
transmission oil temperature gauge (3), excessive torque converter / transmission
oil temperature is indicated. Excessive hydraulic oil temperature is indicated if the
needle is in the red range of the hydraulic oil temperature gauge (4).
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Monitoring system indicators The parking brake alert indicator (2) is a warning category 2S that indicates the
machine is not in neutral and the parking brake is engaged. In warning category 2S,
1. Engine oil pressure alert
indicator Severe damage to components will occur if machine operation is not changed.

2. Parking brake alert indicator

action alarm will sound. This category requires immediate safe shutdown of the
3. Brake accumulator oil pressure machine in order to prevent possible injury to the operator and / or severe damage
alert indicator to the system and the machine. The machine should not be operated until the cause
has been corrected.
4. Electrical system alert indicator
The following are Category 3 warnings:
5. Action lamp
The engine oil pressure alert indicator (1) indicates low engine oil pressure. The
brake accumulator oil pressure alert indicator (3) indicates low brake accumulator oil
6. Engine coolant level alert pressure. If the brake accumulator oil pressure continues to decrease, the parking
indicator brake will automatically engage. The electrical system alert indicator (4) indicates
a serious malfunction in the electrical system. The engine coolant level alert
7. Transmission oil pressure alert indicator (6) indicates low engine coolant. The transmission oil pressure alert indicator
indicator (7) indicates low transmission oil pressure.
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Monitoring system indicators The Caterpillar Monitoring System will perform an automatic self-test at start-up
whenever the key start switch is turned to the ON position. First the Caterpillar
1. Gauge cluster Monitoring System calibrates the gauge cluster (1) and tachometer (2). Prior to the
self-test, the gauge cluster and tachometer go from the initial value to zero.
2. Tachometer

3. Alert indicators operator to visually inspect the indicators during starting.

4. The digital display window (4) will show the following readouts for approximately
three seconds:
5. Digital speedometer
- all indicators of units (Deg C, kPa, miles, kilometers, rpm and liters).
6. Actual gear indicator - “X 10”.
- symbol for the service hour meter.
- “888.8.8.8” in the six digit display area.
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The self-test will also perform the following:

- the gauges in the gauge cluster and tachometer will be calibrated. The
gauges will sweep to half scale and the gauges will return to zero. The
gauges will sweep to full scale and return to operating values.
- the digital speedometer (5) activates every segment of the display and
shows the following readout: “188,” “MPH,” and “km/h.”
- the actual gear indicator (6) for the transmission activates every
segment of the readout and displays a “0” with an “X” and a “+” sign on
top of the “0.”
- the action lamp illuminates.
- the action alarm will sound once.

If any of the alert indicators, action lamp, or digital readouts do not appear, or if the
gauges do not sweep, the electrical system must be inspected. Perform all necessary
repairs before the engine is started again.
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MODES NORMAL MODE

OF - Monitors Machine Systems

During Normal Operation

OPERATION
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OPERATOR MODE SERVICE MODE

- Service Meter - Harness Code
- Numeric Readout
- Odometer - Service
- Tattletale
- Tachometer - Units
- Diagnostic Scrolling - Diagnostic and Programming
- Maintenance Required Indicator Reset

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Modes of Operation

Modes of operation The Caterpillar Monitoring System provides operational, service, and diagnostic
information from the various machine electronic control systems. This information is
displayed in three different “modes” on the monitoring system. These modes provide
information about the condition of the machine and the setup of the monitoring
system.

monitoring system, the main display module performs a self-test as previously

described. After the self-test is completed, the monitoring system enters the NORMAL
mode.

Normal mode The Caterpillar Monitoring System on the R1600G Load Haul Dump operates in the
normal mode during normal machine operation. In the NORMAL mode, the monitoring
system continuously watches the machine systems and displays output information
through the gauges and the digital display windows. Also, when an abnormal
condition exists in any of the monitored machine systems, the Caterpillar Monitoring
System will alert the operator.

Operator mode The operator modes provide additional information about the machine systems and
setup. The operator can select four modes using the operator mode scroll switch in
the operator station.
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Service mode The SERVICE mode includes several modes that provide information concerning the
machine harness code, diagnostic codes, out-of-range gauge readings, and other
machine condition information.

The main display module knows what machine model it is connected to based on the
machine harness code. The harness code (machine code) is the input provided to
the main display module by the open or grounded condition of six wires in the wiring
harness.
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Operator’s station The Operator Modes can be accessed by the operator mode scroll switch (1) located
on the switch panel in the operator’s station.
1.

2. Service connector
any sub-modes available for the selected mode.
3.
The Service Mode can be accessed by using the 4C-8195 Control Service Tool and
4. Diagnostic connector 257-8717 Cable Adapter connected to the service connector (2), which allows the
service mode information to be displayed on the display window (3) of the main
display module. The display window is used to display information from all electronic
control modules on the machine.

NOTE:
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OPERATOR MODE 0 OPERATOR MODE 1

SERVICE METER ODOMETER
MILES

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OPERATOR MODE 3
DIAGNOSTIC SCROLLING

OPERATOR MODE 2 SERV

CODE
DIGITAL TACHOMETER
MID
RPM

SERV
CODE

CID/FMI

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Operator modes: The operator modes are described below:

Service meter mode Service Meter Mode: Shows the total machine operating hours. The main display
module monitors the “R” terminal of the alternator and the engine oil pressure switch

pressure switch, the service meter starts.

Odometer mode Odometer Mode: Shows the total distance the machine has traveled. The distance
is displayed in units of kilometers (KM) or miles (MILES) depending on the settings
in the units mode. The main display module receives information for this output from
the transmission output speed sensor. This information is sent from the Power Train
ECM over the CAT Data Link.

Digital tachometer mode Digital Tachometer Mode: Shows the engine speed in rpm. The information for the
tachometer mode comes over the CAT Data Link from the Engine ECM. The Engine
ECM reads the engine rpm from the engine speed sensor.

Diagnostic scrolling mode Diagnostic Scrolling Mode: Shows any diagnostic codes that are stored in memory
by the main display module. The diagnostic codes representing a system failure
come from any of the ECMs over the CAT Data Link.
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SERVICE MODES
1. Harness Code (Machine Code Mode)
2. Numeric Readout
3. Diagnostic Servicing (Service Mode)
4. Digital Tattletale
5. Units
6. Diagnostic and Programming Mode
7. Maintenance Required Indicator Reset Mode

Service modes The Service Mode includes eight separate modes. These modes are:

1. Harness code 1. Harness Code (Machine Code Mode) - represents the machine model.
2. Numeric Readout - shows an exact digital readout of the information
shown on the quad gauge module.
2. Numeric readout 3. Diagnostic Servicing (Service Mode) - displays machine fault codes.
4. Digital Tattletale - displays the extreme value for each machine parameter.
3. Diagnostic servicing
5. Units - allows information to be toggled between US and metric units.
6. Diagnostic Programming Mode - used to accurately monitor and calibrate
4. Digital tattletale inputs and outputs of certain machine sensors and ECMs.

5. Units maintenance required alert indicator.

6. Diagnostic programming mode

7. Maintenance required indicator

reset mode