ce_drctryfinal

www.catelectronics.com2

Electronics fromCaterpillarCaterpillar Inc. is more than big, heavy

equipment—and much more than yellow

iron. Our products have evolved from simple

mechanical workhorses to sophisticated,

electronically controlled work-site solutions.

At the heart of this transformation are

electronics from Caterpillar.

Caterpillar offers a total solution for custom

electronic control systems, electrical and

operator interface components and asset

management tools. Our custom solutions

enable Caterpillar, Tier I suppliers and

OEMs to provide a powerful point of

differentiation in the heavy-duty industries

they serve. Caterpillar’s strategy is to

develop plug-and-play components with a

common look and feel, so they can be

easily interfaced into products.

Caterpillar provides robust systems,

durable components and reliable solutions

to operate and survive in harsh

environments. Our experts develop,

harness and mobilize our knowledge of

heavy-duty applications to meet your

specific requirements with cutting-edge

components and system solutions.

As a Caterpillar OEM customer, you have

access to an ever-expanding array of

products—this product directory is just a

sampling. Tell us about your application

needs, and our team will outline a solution.

Contact us at:

888-598-8186

[email protected]

Electronic Components

Controller Software

Integrated Systems

We will be the global leader in

providing motion and power

control solutions.

Our Vision

3Electronics Product Directory

TABLE OF CONTENTS

Electronic Control Modules page

Engine Controllers. . . . . . . . . . . . . . . . . . . . . 6-7

A4:E1

A4:E2

A4:E4

Machine Controllers . . . . . . . . . . . . . . . . . . . 8-9

A4:M1

A4:M3

A5:M2

Communications Controllers. . . . . . . . . . 10-11

A4:N1

A4:N2

Asset ManagementMachine Security System . . . . . . . . . . . . 14-15

Electronic Service Tools . . . . . . . . . . . . . 16-17

Visual Operator InterfaceData Link Gauges . . . . . . . . . . . . . . . . . . . . . . 20

Instrument Clusters. . . . . . . . . . . . . . . . . . . . . 21

D1:G9.5

D1:G9.3

D1:G9.1

D1:G1.3

Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23

Advisor Display

Messenger Display

HD Monitor Display

Alarm Horn and Hourmeter . . . . . . . . . . . . . . 24

Alarms and Horns . . . . . . . . . . . . . . . . . . . . . . 25

Forward Warning Horns

Back-up Alarms

Audible Signal Devices

Work Area Vision System (WAVS) . . . . . 26-27

Tactile Operator Interface page

Joysticks and Shifters . . . . . . . . . . . . . . . 30-31

Handles

Joysticks

Levers

Shifters

Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Rocker Switch

Electronic Key Switch

Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Silicone Spring Block

Compression Spring

Governor Pedal

SeatingComfort Seat . . . . . . . . . . . . . . . . . . . . . . . . 36-37

LightingLights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41

HID Flood Lights

3x3 Halogen Flood Lights

Shock Resistant Lights

LED Indicator Lights

LED Signal Lights

LED Combination Rear Signal Lights

Combination Head/Turn Lights

Rotating Beacon

Strobes

Electrical Components page

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-48

Fuel Level Sensor

High Pressure PWM Pressure Sensor

Integral Connector Pressure Sensor

Wire Leaded PWM Pressure Sensors

Hall Effect Active Speed Sensors

High Accuracy Timing Sensors

Low Speed Timing Sensors

PWM Exhaust Gas Temperature Sensors

Exhaust Gas Thermocouples

PWM Temperature Sensors

Active Temperature Sensors

Passive Temperature Sensors

Cylinder Position Sensors

Rotary Position Sensors

Filter By-Pass Switch

Robust Arm Bar Switch

Liquid Level Switch

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

www.catelectronics.com

ELECTRONIC CONTROL UNITS

Our Controllers have been developed for today’s robust applications.

They are capable of advanced control and diagnostics.

This is the most comprehensive line of versatile, configurable and

rugged controllers in use around the world today.

Cat® Electronic Control Units offer powerful capabilities for use in many

mobile OEM and industrial applications.

4

Electronics Product Directory 5

A4 ENGINE CONTROLLERS

6 www.catelectronics.com

A4:E4 ControllersOur range of A4:E4 controllers has been developed withtomorrow’s requirements in mind. Using the latestPower PC technology for advanced high speedprocessing, this range of controllers is capable ofadvanced control and diagnostics.

A4:E2 ControllersThe A4:E2 range of controllers has been developed forthe advanced control requirements. Using Power PCtechnology, the A4:E2 is capable of advanced controland diagnostics.

A4:E1 ControllersThe A4:E1 controller line offers unsurpassedversatility. Using Power PC technology, this controllercan be programmed for applications as varied asimplement control and as an intelligent remote I/Omodule.

Environmental Specifications A4:E1, A4:E2 & A4:E4 Operating Temperature Range - Fuel Cooled -40°C to +110°C

- Air Cooled -40°C to +85°CFuel Temperature* 80°CFuel Flow Rate* 2.5 L/min (max)Radiated Immunity 15.0 kHz to 1.0 GHz @100 V/MStorage Temperature Range (normal) -50°C to +120°COutput Short Circuit Tolerance 75% to 133% (NSV) Nominal System VoltageInput Short Circuit Tolerance Between Input and Batt+/Batt-Humidity Tolerance 115% NSV, 90% relative humidity over operating temperature rangeSalt Spray Tolerance 115% NSV with 5% salt spray for 48 hours at 35°CChemical Splash Immunity Diesel fuel, engine/machine oil & SAE J1455 chemical agentsVibration (shock isolated components tolerance) 8.00 G rms random vibration from 24-2000 Hz in three orthogonal planesMoisture Leakage (sealant pressure tolerance) +/- 35 kPa against water and water vaporElectrostatic Environment Zero damage during exposure to electrostatic painting process*Fuel Cooled housing only

A4:E1 Controller

A4:E2 Controller

A4:E4 Controller

A4 ENGINE CONTROLLERS


Operating Characteristics/SpecificationsStandard HousingAir CooledFuel CooledMilitary HousingInputsSwitch to GroundSwitch to Battery (+Bat)Key Switch On/Boot (+Bat)Analog Input (Active)*Analog Input (Passive)**Analog Input (Active/Passive)Analog Input (Detonation/PWM)PWM Input (Differential)PWM Input (Single Ended)High Frequency Input (Turbo)Analog Input 4-20 mA2-Wire Hall Effect InputsSystem VoltageInput VoltageSensor Power SuppliesAnalog Sensor Supply (8V, 100 mA)Analog Sensor Supply (5V, 200 mA)Analog Sensor Supply (5V, 300 mA)Analog Sensor Supply (5V, 80 mA)Analog Sensor Supply (8V, 70 mA)Digital Sensor Supply (8V, 150 mA)Sensor Supply (12V, 60 mA)Communication Links

On/Off Sourcing Drivers

On/Off Sinking Drivers

PWM Current Drivers

Analog 4-20 mA DriverFrequency Drivers (Speedo/Tacho)Injector Drivers (high sides)Injector Returns (low sides) Processing ElementsMicroprocessorProcessor SpeedFlash ROMSRAMEEPROM

12 11 17 17 172 2 2 2 21 1 1 1 14 8 10 5 103 5 4 3 4

— — 10 5 51 — — — —2 1 5 4 5

— 1 8 2 6— — 1 — 1— — 2 — —— 2 — — —

— — 1 1 1— — 1 1 11 — — — —

— — 1 1 1— — 1 — —3 2 3 2 2

1 (50 mA)1 (1.0 A)

5 (2.0 A)3 (2.0 A/PWM)2 (3.0 A)

4 (300 mA/PWM)1 (2.0 A)

4 (300 mA/PWM) 4 (300 mA/PWM)1 (2.0 A)

10 (300 mA)1 (1.0 A)

3 (2.0 A)

3 (2.5 A)3 (2.5 A)1 (3.75 A)

8 (12V 300 mA)6 (12/24V 300 mA)

5 (2.0 A)3 (2.0 A/PWM)2 (3.0 A)

5 (2.0 A)3 (2.0 A/PWM)2 (3.0 A)

— 6 8 4 4

MPC555 MPC561 MPC561 MPC561 MPC56140 MHz 56 MHz 56 MHz 56 MHz 56 MHz448 KB 2 MB 2 MB 2 MB 2 MB256 KB 256 KB 256 KB 256 KB 256 KB32 KB 32 KB 8 KB 8 KB 8 KB

— — 2 — —2 — 2 2 2

— 2 12 6 6

Yes Yes Yes Yes YesNo Yes Yes No YesNo No Yes No No

A4:E1 A4:E2 A4:E4FF A4:E4HD A4:E4IE

12V/24V 12V/24V 12V/24V 12V 12V/24V

— 1 — — —1 1 — — —

—

— ——


Environmental Specifications A4 & A5 Operating Temperature Range -40°C to +85°CSystem Voltage 12V/24VRadiated Immunity 15.0 kHz to 1.0 GHz @100 V/MStorage Temperature Range (normal) -50°C to +120°COutput Short Circuit Tolerance 75% to 133% (NSV) Nominal System VoltageInput Short Circuit Tolerance Between Input and Batt+/Batt-Humidity Tolerance 115% NSV, 90% relative humidity over operating temperature rangeSalt Spray Tolerance 115% NSV with 5% salt spray for 48 hours at 35°CChemical Splash Immunity Diesel fuel, engine/machine oil & SAE J1455 chemical agentsVibration (shock isolated components tolerance) 8.00 G rms random vibration from 24-2000 Hz in three orthogonal planesMoisture Leakage (sealant pressure tolerance) +/- 35 kPa against water and water vaporElectrostatic Environment Zero damage during exposure to electrostatic painting process

A4 & A5 MACHINE CONTROLLERS

A4:M3 Controller

A5:M2 Controller

A4:M1 Controller

A4:M1 and A4:M3 ControllersOur range of machine controllers has been developedaround our high-speed Power PC technology to offera configurable, rugged controller capable of use in a wide range of applications. With a high density ofbuilt-in I/O and capable of master/slave communication,the A4:M1 and A4:M3 can be used as a stand-alonecontroller or in a system. These controllers areavailable in our standard and military housings for even more rugged applications and EMC sensitive systems.

A5:M2 Electronic Control ModuleThe A5:M2 electronic control module is an electronichydraulic (EH) control module, but it can function as ageneral-purpose control capable of fitting into variedapplications by simply changing the softwareapplication level. A key feature of this unit is theability to configure the inputs and outputs in manydifferent combinations.


A4 & A5 MACHINE CONTROLLERS

Operating Characteristics/SpecificationsStandard Housing

Air CooledMilitary HousingInputsSwitch to GroundSwitch to Battery (+Bat)Config. Switch to Ground/Switch to BatteryKey Switch (+Bat)Neutral Start InputAnalog Input (Active)Analog Input (Passive)Prog. Analog Input (Active/Passive)PWM / Frequency Input / Switch to GroundPWM Input (High Accuracy)Speed Input (Passive)*Programmable 5V/8V Sensor Supply @ 330 mABattery MonitorR-Terminal InputSensor Power Supplies5V Sensor Supply (200 mA)8V Sensor Supply (400 mA)10V Sensor Supply (3 A)Communication LinksCAN Data LinkATAOutputsOn/Off Sourcing Drivers (2.0 A)On/Off Sinking Drivers (300 mA)On/Off Sinking Drivers (2.0 A)PWM Driver, 1 wire (2.0 A)PWM Driver, 2 wire pairs (2.0 A)Processing ElementsMicroprocessorProcessor SpeedFlash ROMSRAMEEPROM

* For single-ended inputs, one line is left open.** Can be separated into 16 individual on/off drivers.

Yes Yes YesYes Yes No

A4:M1 A4:M3 A5:M2

35 25 —3 — —

— — 61 1 11 1 —2 2 —4 3 —

— — 816 11 64 — —6 4 4

— — 21 1 11 1 —

1 1 —1 1 —1 — —

2 1 21 — 1

6 4 —8 8 —

— — 410 8 —2 — 8**

— — —MPC555 MPC555 MAC 713140 MHz 40 MHz 40 MHz2 MB 2 MB 512 KB

256 KB 256 KB 160 KB32 KB 32 KB 32 KB

COMMUNICATIONS ELECTRONIC CONTROL UNITS


Electronic Control UnitsThese modules enable network access toinformation and operating parameters. The ECUshave communications architecture that can replacemany of today’s purpose-built applications andprovide almost limitless possibilities for futureapplications.

A4:N1 Features include:

• Scheduled reporting• Product service meter hours• Synchronized clock strategy for

hourmeter tracking• Product Location Services/GeoFencing• Machine Information Services

(fuel, events/diagnostics, etc.)• Digital I/O services• On-board status and administration• Wireless communication link status• Power management• Start and Stop times reporting• All on-board ECU hardware and software

information reporting• Configurable parameter requests• Software Enabled Attachments• Data Link support

A4:N2 Features include:

• J1939 network bridging• CAN extension bridging• Proprietary Cat Data Link boost• Proprietary Cat Data Link to Modbus translation• J1939 to Modbus translation• User configurable parameters for translation• User configurable Web pages • Cat service tool communications adapter• Replaces Caterpillar Customer

Communication Module • Replaces Engine Vision Interface Module • Replaces Global Position System Interface Module

(NMEA-183)• Sea Water Temp and Depth translation to Cat Data

Link and J1939 (NMEA-183)


Environmental Specifications A4:N1, A4:N2 Operating Temperature Range (ambient) A4:N1, -40°C to +85°C

A4:N2, -40°C to +75°CStorage Temperature Range (Normal) -50°C to +120°CRadiated Immunity 15.0 kHz to 1.0 GHz @ 100 V/MOutput Short Circuit Tolerance 75% to 133% (NSV) Nominal System VoltageInput Short Circuit Tolerance Between Input and Batt+ / Batt-Humidity Tolerance 115% NSV, 90% relative humidity over operating temperature rangeSalt Spray Tolerance 115% NSV with 5% salt spray for 48 hours at 35CChemical Splash Immunity Diesel fuel, engine/machine oil & SAE J1455 chemical agentsVibration (shock isolated components tolerance) 9.80 G rms random vibration from 24-2000 Hz

in three orthogonal planesMoisture leakage (Sealant pressure tolerance) +/- 35 kPa against water and water vaporElectrostatic environment Zero damage during exposure to electrostatic painting process

Operating Characteristics/SpecificationsExternal Power Supply8V Sensor Power Supply (optional) 1 1CommunicationJ1708 (ATA) Data Link or (CDL) 1 1CAN 2.0 Data Link — 2J1939 CAN Data Link 2 —RS-232 Serial ports (1 w/ DTR, DCD) 3 3 (1 Opto

Isolated)RS-485/422 1 1 (1 Opto

Isolated)Ethernet — 1Processing and MemoryMPC561 Microprocessor 56 MHz —MPC555 Microprocessor — 40 MHzFlash ROM 4 MB 4 MBSRAM 4 MB Max. 4 MB Max.BBRAM 2 MB Max. 2 MB Max.EEPROM 32 KB Max. 32 KB Max.Real-Time Clock 1 1InputsSwitch to Battery wake up input 1 1Key Switch (+Bat) 1 1PWM/Frequency/Switch to Ground Inputs 14 6Analog Input 2 —Alternator R-Terminal Input 1 —OutputsOn/Off Sinking driver (300 mA) 4 4

A4:N1 A4:N2

COMMUNICATIONS ELECTRONIC CONTROL UNITS


ASSET MANAGEMENT


Caterpillar has developed powerful tools for you to

track the performance, locationand service intervals of your fleet in any

environment. The Electronic Service Tool enables

service technicians to assess a machine’s

performance and health from any system

quickly and accurately. This onsite

evaluation may help reduce a machine’s

downtime and improve thesafety of your operators.

Our Machine Security System protects nearly all

brands of equipment, regardless of time or location.

This system allows you to manage access to machines to prevent theft

and limit unauthorized use for rental fleets and equipment owners.

These asset management tools help your fleet continue “business as usual.”


MACHINE SECURITY SYSTEM (MSS)

Stolen equipment is lost productivity. Protect yourequipment against theft by installing the Cat MachineSecurity System. Other systems promote the ability totrack stolen equipment, but that doesn’t preventthievery and the subsequent production loss. Don’twaste your time recovering equipment. Stop machinetheft upfront with Machine Security System.

The Cat system protects nearly all brands ofequipment, regardless of time or location. It guardsagainst theft by disabling a machine’s starting system.Thieves cannot bypass the starting system becauseMachine Security System is integrated into theelectronics. Only a key with your unique code canstart the machine.

Protecting Your Investment• Deters theft• Easily installed on Cat and other brands

of equipment• Cat designed and integrated into the

electronic system• Potential insurance savings due to

increased machine security

How the System WorksEach Machine Security System key contains a uniqueidentification number. The machine electronic controlmodule checks the key being inserted against apre-approved list of keys you have authorized. If thekey is on the list, the machine will start.

This method is superior to much simpler add-on theft deterrent devices. Its sophisticated design isintegrated into the electronics of the machine, making it virtually impossible to defeat.


MACHINE SECURITY SYSTEM (MSS)

Controlling Machine AccessMachine Security System has programmable featuresto allow you to manage access to your machines.• Limits operators to selected machines• Controls the days and hours equipment may be

started, which guards against unauthorized‘weekend use’ of equipment

• Controls access by untrained operators orunauthorized personnel, reducing injury risk

• Programmable for active and inactiveperiods, such as disarming the systemduring regular work hours when a standardkey can be used and then reverting to asecurity key after hours

• Programmable so a key will expire on a certaindate and will no longer start the machine

The Key to Theft Deterrance• Equipment can be started using only the

Machine Security System key with its uniqueidentification number

• The security keys are either yellow or gray, whilestandard keys are black

• This Cat theft deterrent system can be programmedso one key can operate any machine in your fleet

• A machine can be programmed to accept up to 255unique security keys

Availability• Factory available for many models• Can be field installed on Cat machines and other

brands of equipment• Works on both 12- and 24-volt systems

DASH LIGHT

MACHINE SECURITY SYSTEM KEY

ENGINE OR TRANSMISSIONELECTRONIC CONTROL

MODULE

MACHINE SECURITY SYSTEMELECTRONIC CONTROL MODULE


ELECTRONIC SERVICE TOOLS

Electronic Service ToolThe PC-based service tools from Caterpillar providethe capability to access Electronic Control Modules(ECMs) from a personal computer. Many job-criticaltasks can be performed with an electronic servicetool. The user can display the status of a group ofparameters (temperatures, pressures, etc.)simultaneously, view active and clear loggeddiagnostics, display the current configuration of anECM and much more. The service tool works with acommunication adapter to allow connection to anECM. A graphical interface makes this software quickto learn and easy to use. A separate pull-down menufor each function enhances the “ease of use.” Theversion and identification of the ECM is automaticallyretrieved and is displayed on a summary screen whenthe program is started. Diagnostic tests andcalibrations can also be performed.

Caterpillar® PC-based tools enable service techniciansto reprogram ECMs, reconfigure control systemparameters, fine tune performance or diagnose theroot cause of a failure the first time. These powerfultools allow service personnel to display and analyzevital performance and health information from anysystem quickly and accurately. The service toolcommunicates with any system using ATA (J1708),J1939 or the Caterpillar proprietary data linknetworks. The service tools provide information andfeatures needed to help a technician diagnoseproblems and perform repairs and to customize andpersonalize the operation of a product. By allowingcustomers to design flexibility and configurability intoa product, Caterpillar service tools stretch beyond thecapabilities of preprogrammed ECMs or onboarddisplay systems.


ELECTRONIC SERVICE TOOLS

Features and Benefits• Display, graph and log status parameters. • Retrieve prognostic data including histograms,

engine totals for fuel used and miles traveled.• View active diagnostics and clear logged

diagnostics. View events where irregularities haveoccurred and have been logged by the ECM.

• Perform calibrations to enhance performance of the ECM.

• Customize the ECM with application-specificsettings.

• Over 100 custom Diagnostic, Information andService features including:- 2D and 3D Histogram plotting capability (engine

software support required).- Custom Status screen groups- Snapshots (Download and display snapshot data

recorded by the ECM) - Configuration Aid that allows upload/download of

same configuration to multiple control modules• Languages currently supported: Danish, English,

French, German, Italian, Japanese, Portuguese and Spanish.

• Report and Printing capabilities

Customized Service Tool Options• Customized graphics for the splash screen and icons• Customized service tool name• Customized installation• Aftermarket differentiation, i.e., the tool for one

customer does not work on the product of anothercustomer.

• Licensing options for customer management• Flash programming of the ECM(s)• Training demonstration allows familiarity with

the tool’s primary functions without connecting to ECM(s)

• Major operating systems support (MicrosoftWindows 95, 98, NT 4.0, 2000, ME, & XP)

• Perform customized diagnostic tests to identifyharness problems, cylinder or component failures(Automatic Cylinder Cutout with cylinder to cylinderfueling comparison)


VISUAL OPERATOR INTERFACE


Caterpillar is a world leader in providing motion and power

control solutions. We earned this honor through continuous,

advanced research and development, quality engineering and extensive design testing.

Our robust, highly flexible line of displays and instruments are powerful

enough to provide detailed diagnostic and status information for increased

efficiency and reduced downtime. Designed with intuitive navigation and operation, these products provide vital data to operators

with increased visibility.


DATA LINK GAUGES AND GAUGE CONTROLLER

Data Link GaugesThis SAE J1939 Data Link system is composed of digitallycontrolled analog-style gauges that combine the accuracy anddependability of electronics with the simplicity and visual clarityof conventional analog gauges. The system is designed for “plugand play” installation on various applications in many harshenvironments including waste and refuse, petroleum, materialhandling, agricultural and fire and rescue.

Gauge ControllerThe Gauge Controller receives, translates and resends the J1939information via a local data link to the appropriate gauge whileproviding a single interface to the data link for the gauge system.The user can mount the controller on the rear of any 3" gauge orin a separate location if the panel location does not allow spacefor the gauge controller and harnessing to be attached.

Operating Temperature Range -40°C to +85°CStorage Temperature Range -55°C to +85°CVibration 9.8 G rms random vibration from 24 Hz to 2000 HzSeal Sealed to +/- 35 kPa against water and water vaporOutput Short Circuit Tolerance 75% to 133% (NSV) Nominal System VoltageInput Short Circuit Tolerance Between Input and Batt+Humidity Tolerance 115% NSV, 90% relative humidity over

operating temperature rangeSalt Spray Tolerance 115% NSV with 5% salt spray

for 48 hours at 35°CChemical Splash Immunity Diesel fuel, engine/machine oil

& SAE J1455 chemical agentsElectrostatic Environment Zero damage during exposure to

electrostatic painting process

Environmental Specifications

FeaturesAuxiliary Pressure (0 -3447 kPa)Auxiliary Temperature (-40°C to 49°C)Backlighting (Switch to battery input)Boost Pressure (0-345 kPa)Engine Coolant (-18°C to 120°C)Exhaust Temperature (49°C to 872°C)Fuel Level (0 - 4/4)Fuel Pressure (0 - 862 kPa)Fuel Rate (0 - 757 lph)Fuel Temp (-18°C to 120°C)Inlet Manifold Temp (-18°C to 120°C)LCD DisplayOil Pressure (0 - 689 kPa)Oil Temperature (-18°C to 120°C)Percent Load (0 -100%)Speedometer (0-70 mph, 0-110 km, 0-60 knots)Tachometer w/LCD (0-3000 rpm, 0-3600 rpm and 0-4000 rpm gauges are available)

Transmission Oil Pressure (0 - 3447 kPa)Transmission Oil Temperature (-18°C to 120°C)Volt

Operating Characteristics/Specifications

Data Link Gauges

Yes —Yes —Yes YesYes YesYes YesYes YesYes —Yes YesYes YesYes YesYes Yes— Vehicle or Engine HoursYes YesYes YesYes Yes— Yes— Yes

Yes YesYes Yes

0V-32V 9V-32V

2" Gauge 3" Gauge

Supply Voltage:Gauge Controller Operating Supply Voltage Range (+Bat Input) 9V-32VGauge Operating Supply Voltage (Supplied by Gauge Controller) 9V-18VCommunication:J1939 CAN Data Link 1Gauge Data Link 1

Operating Characteristics/Specifications Gauge Controller

Data Link Gauges

Gauge Controller


INSTRUMENT CLUSTERS

Instrument ClustersCaterpillar has designed instrument clusters withrobust features to endure the cold, heat and humidityof today’s harsh work environments. Communicatingon the SAE J1939 data link, the clusters are able toprovide critical operating information to the userwhile the machine or engine is in use, 24 hours a day,seven days a week. The clusters include LED indicatorlights, LCD digital displays and backlighting.

D1:G9.3D1:G1.3D1:G9.5

Environmental Specifications Operating Temperature-20°C to +70°C — — — Yes-40°C to +85°C Yes Yes Yes —Storage Temperature -40°C to +85°C Yes Yes Yes —-20°C to +75°C — — — YesVibration9.8 G 24-2000 Hz Yes Yes Yes YesSealing/ProtectionSealed to IP65 Front, IP52 Rear Yes Yes —Sealed to IP65 Front and Rear Yes — — —Sealed to IP66 Front, IP52 Rear — — — Yes

Operating Characteristics/SpecificationsInputs/OutputsGeneric Switch to Battery 4 1 — —Keyswitch Input 1 1 1 1Output Horn Driver 1 1 1 1CommunicationData Links 1 1 1 1Electrical Power Supply 9V-32V 9V-32V 9V-18V 9V-32VPhysical CharacteristicsDimensions LCD 110 mm x 40 mm LCD 110 mm x 40 mm LCD 89 mm x 25 mm LCD 55 mm x 39 mmWeight 1.51 kg — — —Mounting Type Panel Panel Panel PanelMonochrome Transflective LCD Display Yes Yes Yes Yes (Interactive)LED Indicators 18 12 16 (Basic) 17Backlighting White Amber Red RedConnectors35 pin environmentally sealed (Ampseal) — — — Yes12 pin environmentally sealed integral DT — Yes Yes —24 pin environmentally sealed integral DT Yes — — —

D1:G9.5 Gen II Cluster D1:G9.3 CIC Cluster D1:G9.1 SSL Cluster D1:G1.3 CWL Cluster

D1:G9.5 Gen II Cluster D1:G9.3 CIC Cluster D1:G9.1 SSL Cluster D1:G1.3 CWL Cluster

D1:G9.1


DISPLAYS

D3:M3Advisor Display Unit

D3:M2Messenger Display Unit

AdvisorAdvisor 6.0m2 is a monochrome, LCD graphicalinformation display capable of displaying real timeoperating information on parameters such as RPMspeed and fuel consumption, and is targeted for use inheavy-duty operating conditions. The displayed data canbe obtained from an existing data link that connectsengines, transmissions and hydraulic systems.

MessengerThe Messenger operator information display providesreal-time visual feedback on operating conditions to helpensure the best performance possible from yourequipment. Messenger uses a full graphics informationdisplay with transflective LCD technology. Multiplecommunication data links can be utilized to provide real-time performance and operating information while theequipment is in use. The information can be displayed ineither multilingual text (even graphical languages) or agraphical format.

HD Monitor DisplayThe HD Monitor Display provides current coloroperating data. The HD Monitor Display unit is compact,durable and protected against adverse temperaturesand environments. The HD Monitor Display canaccommodate up to three users with five screens each.These screens can display parameter data in analog,bar graph or digital form. The following data isavailable to users: RPM, Hours, Load, Pressure,Temperature and more operating parameters.

D3:C4HD Monitor Display

Environmental Specifications-20°C to 70°C-40°C to 85°C-20°C to 75°C-40°C to 85°C-50°C to 85°C4.3 G 24-2000 Hz9.8 G 24-2000HzSealed to +/- 35 kPaG case, IP68/NEMA 13

Operating Temperature

Storage Temperature Range

Vibration

Sealing/Protection

D3:M3 D3:M2 D3:C4Advisor 6.0m2 Messenger HD Monitor Display

— — YesYes Yes —— — YesYes — —— Yes —— — YesYes Yes —Yes Yes Yes


DISPLAYS


1 — —1 1 1

— — 12 — —8 — —4 — —1 — —

— 1 —

1 — —3 3 2

68376 Mot. 68376 Mot. —32 bit @ 24 MHz 32 bit @ 24 MHz

2 MB 512 KB 32 KB1 MB 1 MB 512 KB32 KB 32 KB 32 KB

Yes Yes Yes

9V-32V 9V-32V 9V-32VYes — —Yes — —

71 x 140 x 221 mm 60.5 x 66 x 119.5 mm 147.9 x 228.6 x 47.65 mm1.59 kg 0.27 kg 1.81 kg

Panel/Gimbal Panel/Gimbal Panel/GimbalYes Yes YesYes — —

White White/Red Red10 4 4— CE CE, BV, DNV, LR,

G2, ABS

Yes — —— Yes —— — Yes

Inputs/OutputsGeneric Switch to BatteryKeyswitch InputOutput Horn DriverHigh Side DriversPWM Switch to Ground Analog Voltage Switch to GroundR-terminal Alternator InputPWM InputsCommunicationRS 232Data LinksProcessing Elements

Processor

RAM/SRAMFlash MemoryEEPROMScreen Builder ToolElectricalPower Supply10 +/- 1V Supply (Output)5V Regulated Supply (Output)Physical CharacteristicsDimensionsWeightMounting TypeMonochrome Transflective LCD DisplayLED IndicatorsBacklightingButtonsApprovals

Connectors70 pin environmentally sealed8 pin environmentally sealed integral DT12 pin environmentally sealed integral DT

D3:M3 D3:M2 D3:C4Advisor 6.0m2 Messenger HD Monitor Display

Screen Builder ToolScreen Builder Tool is a Windows-based tool for screenlayouts. You can choose from a variety of offerings ofgraphics for multiple screen layouts for each application.Screen builder software is compatible with Windows95/98/NT 4.0, Windows 2000 PC operating systems andis J1939 compatible.

ALARM HORN AND HOURMETER


Alarm Horn and HourmeterThe Hourmeter allows an operator to determine thehours spent on a machine or engine. The Alarm Hornalerts an operator of an active diagnostic condition orevent on a machine or engine. The J1939 CAN DataLink Communication provides the ability of theHourmeter and Horn to receive information fromvarious ECUs or controller modules.

Environmental Specifications Alarm HornOperating Temperature -40°C to +85°CStorage Temperature -55°C to +85°CSupply Voltage Range 9V-32VOutput Short Circuit Tolerance 75% to 133% (NSV) Nominal System VoltageHumidity Tolerance 115% NSV, 90% relative humidity over operating temperature rangeSalt Spray 115% NSV with 5% salt spray for 48 hours at +38°CChemical Splash Diesel fuel, engine/machine oil & SAE J1455 chemical agentsVibration 9.8 G rms random vibration from 24-2000 Hz in three orthogonal planesShock 15.0 G rms in three orthogonal planesMoisture Leakage +/-35 kPa against water and water vaporElectrostatic Environment Zero damage during exposure to electrostatic painting processButton Endurance 500,000 cycles

Environmental Specifications HourmeterOperating Temperature -40°C to +85°CStorage Temperature -55°C to +85°CSupply Voltage Range 9V-32VOutput Short Circuit Tolerance 75% to 133% (NSV) Nominal System VoltageHumidity Tolerance 115% NSV, 90% relative humidity over operating temperature rangeSalt Spray 115% NSV with 5% salt spray for 48 hours at +38°CChemical Splash Diesel fuel, engine/machine oil & SAE J1455 chemical agentsVibration 9.8 G rms random vibration from 24-2000 Hz in three orthogonal planesShock 15.0 G rms in three orthogonal planesMoisture Leakage +/-35 kPa against water and water vaporElectrostatic Environment Zero damage during exposure to electrostatic painting process

InterfacesElectrical Power Input 9V-32VData Input 2 linesConnectors Deutsch DT style 6-pin integral connectorFunctionsAlarm Acknowledge Button YesLED Warning Indicator Self-test on start upHorn Test Self-test diagnostic on power upExternal Horn Driver 300 mA @ 12V/24VHorn CharacteristicsFrequency 2900 Hz +/-500 HzSound Pressure Level 90-100 dB at 60 cm

Operating Characteristics/Specifications Alarm Horn

InterfacesElectrical Power Input 9V-32VData Input 2 lines and a shieldConnectors Deutsch DT style 6-pin integral connectorLCD DisplayBack Lighting White or Red LED technologyZero Delay Response Time -20°C and aboveDisplay Type Transflective, positive modeData Link CommunicationType J1939 CAN

Operating Characteristics/Specifications Hourmeter

Hourmeter

Alarm Horn


ALARMS AND HORNS

Alarms and HornsThe Audible Alarms product line consists of threemain product categories—forward warning horns,back-up alarms and audible signal devices. The DiscHorn and Trumpet Horn are mounted at the front ofthe vehicle to warn of forward motion. The FixedLevel and Self-Adjusting alarms are mounted at theback of the vehicle to warn of reverse motion. Self-Adjusting alarms change sound level outputaccording to the surrounding sound level. Our panelmount audible signal devices are piezoelectric whilebracket mount devices are electromechanical.

Operating Characteristics/Specifications Supply Voltage 12V/24V 12V/24V 12V/24V 12V/24V 12V/24V 24VSupply Current <1 A <1 A <1 A <1 A 4.5 A 6 ALoudness 90 dB @ 1.0 M 78-92 dB @ 0.61 M 97/107/112 dB @ 1.2 M 87-112 dB @ 1.2 M 108 dB @ 2 M 114-119 dB @ 3 MTone 500 Hz 2900 Hz 1200 Hz 1200 Hz 335/400 Hz 328 Hz

Environmental SpecificationsOperating Temperature -20°C to +60°C -20°C to +60°C -20°C to +60°C -20°C to +60°C -20°C to +60°C -20°C to +60°CStorage Temperature -50°C to +85°C -50°C to +85°C -50°C to +85°C -50°C to +85°C -50°C to +85°C -50°C to +85°CSealing Spray Wash Spray Wash 34.5 kPa

Bracket Panel Fixed Level Self-Adjusting Disc Trumpet Mount Mount Alarm Alarm Horn Horn

Disc Horn

Backup Alarm Bracket Mount Signal Device Panel Mount Signal Device

Bracket Panel Fixed Level Self-Adjusting Disc Trumpet Mount Mount Alarm Alarm Horn Horn

WORK AREA VISION SYSTEM


The new, versatile Caterpillar Work Area VisionSystem (WAVS) can provide machine operators withviews from up to 3 cameras through advancedswitching algorithms.

While not intended to be used in place of direct viewsor installed mirrors, WAVS is a great asset foroperators at any level.

Developed specifically for rugged applications and environments, the Caterpillar Work Area VisionSystem is simple to install on any machine and is easy to use—yet offers powerful capabilities and features:

• Improves productivity • Increases operator awareness of surroundings, work

tool activity and changing work area conditions

7" (178 mm) Color LCD Display• Auto-sense illumination for changing

light conditions• Rugged mounting is user-adjustable

Camera• Robust design withstands vibration and

pressure washing • Includes internal heater for removal of

condensation, snow and ice• Photochromic lens darkens in ultraviolet

light exposure• 2 camera views available:

- Panoramic 115°- Narrow 78°

27

WORK AREA VISION SYSTEM

Electronics Product Directory

Operating Characteristics/ WAVSSpecificationsSystemSupply Voltage +11V to +32VCurrent 1.5 A max. (12V system) for 3 camera system

1.0 A max. (24V system) for 3 camera systemDisplayType 7" (178 mm) color TFT (Thin Film Transistor) LCDResolution (480 x 3) x 234 pixelsAspect Ratio 16:9Luminance 400 Cd/m2 (adjustable down to 4 Cd/m2)Weight 2.3 kgDimensions (w/o bracket) 175 mm L x 125 mm H x 70 mm D

Note: 25 mm D without sun cover Sealing IP54 (withstands splash, but not immersion)Operating Temperature -40°C to +75°CCameraType Color .25" (6.35 mm) CCDPicture Elements 512 (H) x 582 (V)Light Sensitivity 0.5 luxViewing Angle (degree)

Standard 115° (H) 86° (V)Optional 78° (H) 52° (V)

Weight 420 gDimensions (w/bracket) 66 mm H x 77 mm W x 55 mm DSealing IP69K, DIN-IEC 529 (withstands high pressure wash and immersion)Operating Temperature -40°C to +75°CSwitcherType Solid stateInputs 3 (prioritized)Outputs 1Weight 134 gDimensions 134 mm L x 36 mm W x 31 mm HSealing IP67Operating Temperature -40°C to +75°CCable

Video cables are available in a variety of lengths for installation on any size machine


TACTILE OPERATOR INTERFACE

Electronic products from Caterpillar are designed and tested to

perform in and withstand the harshest operatingenvironments. Our broad experience and understanding of

heavy-duty application environments—severe vibration and

shock, extreme operating temperature ranges, humidity,

corrosion, excessive dust—have been taken to the

testing process to provide state of the art solutions.

We not only understand the outside environment, but

we also understand the operator’s environment. Our

joysticks, levers, switches and pedals have all been

designed to improve the experience andproductivity for the operator.


Handles, Joysticks, Levers and ShiftersOperators want their machines to look, feel, drive andride more like their personal vehicles. The Caterpillarline of Handles, Joysticks, Levers and Shifters has beendeveloped using highly reliable electroniccomponents to satisfy that operator requirement.

The product line is comprised of the following:

Column Mounted Shifters have a five-million cycle lifeexpectancy and two-million cycle speed capability.The reliable electronic shifters and shuttles fortransmission direction and speed input are data linkready and exhibit excellent environmentalperformance.

The Handles, Joysticks and Levers are modularlydesigned allowing for application customization whileminimizing development time, cost and tooling. Theproducts have a long life expectancy. The handles andjoysticks are ruggedly-designed making them morereliable than other commercially-available productsand the serviceable modules reduce customer costs.

Prophet Handle

Column Mounted Shifter

Electronic Joystick

JOYSTICKS AND SHIFTERS

S4 Handle S7 Handle Single Axis Lever


JOYSTICKS AND SHIFTERS


9V-32V 9V-32V 9V-32V 7V-11V 7V-11V 9V-32V100 mA max 105 mA <30 mA at 32V <30 mA at 32V <30 mA at 32V <30 mA at 32V

<100 mA at 9V <100 mA at 9V <100 mA at 9V <100 mA at 9V

— 500 Hz 500 Hz Up to 2 available Up to 2 available 1 output4 outputs available

Yes 3 available 5 available Up to 5 available Up to 2 available —Yes — — — — —— 1 degree 0.3 degree 0.3 degrees 0.3 degrees 0.3 degrees

+/- 15 degrees — +/- 17 degrees Roller travel +/- 6 mm Roller travel +/- 6 mm +/-25 degrees3 Nm torque — 3 Nm torque 6 mN-m 6 mN-m 0.2 N-m

InputsSupply VoltageSupply Current

OutputsOutput Signal (PWM)

Output SwitchedOutput Signal (20mA-2.0A direct drive)ResolutionMechanicalRotationForce

Column Mounted Prophet Electronic S4 S7 Single AxisShifter Handle Joystick Handle Handle Lever

Chemical Compatibility

Temperatures

Vibration

EMI/RFI

Sealing

Life

Connector

Column Mounted Prophet Electronic Shifter Handle Joystick

Diesel Fuel Yes Yes YesWater Yes Yes YesEngine Oil Yes Yes YesTri-Sodium Phosphate Cleaners Yes Yes YesOperating -40°C to +85°C -40°C to +85°C -40°C to +85°CStorage -50°C to +85°C -40°C to +85°C -40°C to +85°C9.8 G random, three axis — Yes Yes8 G rms 24-2000 Hz, three axis Yes — —Meets EU requirements — Yes Yes100V/m radiated (15 kHz to 1 GHz) Yes — —+/- 35 kPa — Yes Yes10.4 kPa water spray Yes — —Direction 5 million cycles — 2.5 million cyclesSpeed 2 million cycles — —Integral 12 pin DT Yes — —


Environmental SpecificationsOperating Temperature Range -40°C to +85°C -40°C to +85°C -40°C to +85°CStorage Temperature Range -50°C to +85°C -50°C to +85°C -50°C to +85°CVibration 9.8 G rms, 3 axis 9.8 G rms, 3 axis 9.8 G rms, 3 axisEMI/RFI Meets EU Requirements Meets EU Requirements Meets EU RequirementsSealing +/-35 kPa +/-35 kPa +/-35 kPaLife Direction Button 1 million, Roller 1.5 million Button 1 million, Roller 1.5 million 6 million cyclesConnector Type Deutch 12 pin Deutch 12 pin Deutch 6 pinChemical Compatibility

Diesel Fuel Yes Yes YesWater Yes Yes YesEngine Oil Yes Yes YesTri-Sodium Phosphate Cleaners Yes Yes Yes

S4 Handle S7 Handle Single Axis Lever


SWITCHES

Rocker Switches

SwitchesThe Caterpillar family of switches offers componentssuch as the Rocker Switch to allow the operator totransfer input, such as activation of a lockingmechanism, to the electronic control module orcomponent in a cost-effective manner.

The Electronic Key Switch operates the on-off switch viaa removable key.

Electronic Key Switch Operating Characteristics/Specifications

ElectronicRocker KeySwitch Switch


Standard Specifications

Protection

Vibration

Rocker ElectronicSwitches Key Switch

-50°C to +85°C -50°C to +85°C-40°C to +85°C -40°C to +85°C

+/-35 kPa —— YesYes —

Storage TemperatureOperating TemperatureSealing9.8 G rms 24-2000 Hz three axis10 G, 10 to 500 Hz

InputsSupply VoltageLeakage CurrentOutputsOutput SignalProtectionMechanicalLifeContact ConfigurationElectricalLife at max. currentMax LoadResistiveInductiveLamp

12V-24V 9V-16V— 6 mA max

— Switch to +Battery— 5 A fuse

min. 250,000 cycles —12 A @ 28V 0.5 A @ 24V

50,000 cycles —

12 A —12 A —5 A —


PEDALS

PedalsUtilizing our Rotary Position Sensors, the Caterpillar lineof pedals is designed for rugged, harsh environmentswhile maintaining a long life cycle of 3 million cycles.Operators appreciate the durability as well as the easeof use.

Environmental Specifications Chemical Compatibility

Diesel Fuel Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4)Water Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4)Engine Oil Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4)Antifreeze Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4)

Operating Temperature Range -40°C to +85°C -40°C to +85°C -40°C to +85°CStorage Temperature Range -50°C to +85°C -50°C to +85°C -50°C to +85°CLife Cycle 3 million cycles 3 million cycles 3 million cycles

Operating Characteristics/SpecificationsInputsSupply Voltage 8.0V +/-1% 8.0V +/-1% 8.0V +/-1%Supply Current 30 mA max 30 mA max 30 mA maxOutputsOutput Signal at Neutral (% duty cycle) 10% to 22% 36.5% 10% to 22%Output Signal at Full Activation (% duty cycle) 75% to 90% 58.0% 75% to 90%ElectricalConnector Integrated 3-pin DT Integrated 3-pin DT Integrated 3-pin DTMechanicalPedal Force at Start 44 N 44.5 N 22 NPedal Force at Full Travel 222.4 N 222.4 N 44 NTreadle Angle 45° +/-2° 45° +/-2° 45° +/-2°Treadle Displacement 17° +/-2° 17° +/-2° 17° +/-2°Treadle Color Red Red Black

Silicone Compression Governor Spring Block Spring Pedal

Silicone Spring PedalGovernor Pedal

Compression Pedal

Silicone Compression Governor Spring Block Spring Pedal


SEATING

The Cat Comfort Seat delivers the most support and durabilityyou'll find on any equipment. The tough, heavy-duty construction combined

with ergonomic–designed features and extra thick, contoured

cushions will provide the operator maximum comfort and reduce fatigue.

Cat Comfort Seats and operator restraint systems provide optimum fitto keep the operator securely positioned during machine operation. And,

with a “seat life” expectancy three times that of the competition, the Cat

Comfort Seat provides a cost–effective solution for increasedoperator comfort, satisfaction and productivity.


SEATS

Cat Comfort Seat• Operator Satisfaction—Designed to meet comfort,

support and restraint needs for operators who share“around the clock” work schedules.

• Comfortable—Ergonomic high-back design and extra-thick, contoured cushions provide maximum operatorcomfort and productivity.

• Supportive—Fit and positioning are similar to that of a personal vehicle or small truck. A three-pointshoulder belt keeps the operator comfortablypositioned and secured.

• Adjustable—Seat levers and controls are within easyoperator reach. Dual Retractor Belt System keepsoperators of any size comfortable and secured.

• Durable—Proven Toggle Link Suspension has beencombined with a “durability through simplicity”designed seat assembly. This allows for minimalmaintenance and a tighter fit of components over theservice life of the seat. The seat and suspension havebeen designed by 10,000-hour life.

• Tested—Over 40,000 hours of testing in rugged highhour off-highway applications, including 5,000 lb. in-cab seat belt pull tests.

Dual Retractor Belt System• Keeps operator in the seat for a secure ride• Meets SAE J386 and SAE J2292 specifications• Bright orange shoulder belt is easily visible when

properly worn and latched• Six vertical adjustment positions provide optimum fit

for a wide range of operator heights• Emergency Locking Restraint (ELR)—shoulder belt

functions “sense and lock” when conditions demand• Lap belt comfort with Automatic Locking Restraint

(ALR)—the lap belt automatically locks into position,but still allows operator movement without cinching

Proven Toggle Link Air Suspension• Optimal “Ride Zone” positioning is accomplished by

adding (or removing) air to the proven Toggle Link AirSuspension

• An indicator gauge makes it easy for the operator to see the correct amount of air has been added tothe system

• Once adjusted, the seat will maintain the correctsetting with no further adjustment until a shift change

• The Toggle Link Air Suspension system has beenproven extremely durable in the most ruggedapplications, with over 10,000-hour life expectancy


SEATS

Cushions• A negative rake feature allows operator a cushion

tilt adjustment (10-15°), even while the operator is in the seat

• Side bolsters on upper cushion help keep operator in seat in rough applications

• Cushion density designed for shift-long comfort• Cushions use a waterproof foam-in-place technology

that is easily cleaned• Upper and lower cushions are individually

replaceable

High-back design provides additional head andneck support for maximum operator comfort

Infinitely adjustablelumbar support

Fully adjustable arm restscan be “flipped up” andout of the way when notin use (dual arm rests areavailable only on certainapplications)

Proven Toggle Link AirSuspension Systemcompensates for theoperator’s weight andprovides maximumsuspension travel

Cast gears for long lifeand durability

Dampener adjustmentallows the operator totune the suspension tofive “firmness” settings

Lower cushion tiltadjustment helps reduceoperator fatigue and fits awider range of operatorsizes

Dual Retractor BeltSystem with highly visibletwo-inch orange shoulderbelt which is easily seenwhen properly worn andlatched

Extra-thick, contoured cushions withspecial side bolsters keep the operatorpositioned in the center of the seat

Adjustment levers are at the front of theseat for easy operator reach


LIGHTING

Developed and tested to withstand the toughest environments, the

electronic components from Caterpillar are widely considered to be some

of the most durable available. From the frigid Antarctic chill to

searing Arabian Peninsula heat, our rugged products consistently

perform and withstand high-working cycles.

For work sites requiring 24/7 operation, quality lighting iscritical. Our robust line of work lights may help improve the work

site visibility for operators and may improve their safety on the job.

3X3 HalogenHID Flood Lights


LIGHTS

Today, operators demand well-lit work areas usinghighly-reliable lights for safety and performance. TheCaterpillar Lighting product line satisfies these userrequirements by offering the following:

Work Lights The High Intensity Discharge Gas Lights are used forexterior flood lighting. The color of the light is closerto sunlight than traditional halogen thus providing anincrease in operator safety. The HID light is moreefficient as it can produce the equivalent of severalhalogen lights of the same wattage. The gas tube inHID lights has a life expectancy of 2000 to 6000 hours.The 3x3 Halogen Flood Lights are rigid mount lightsdesigned with an advance optical reflector thatprovides light output nearly approaching that of a 5x5 Flood Light. Shock Resistant lights are designedfor general flood lighting. The lens and halogenburner are shock mounted for long-life in highvibration applications and can be mounted eithervertically or suspended.

Head/Turn Lights With high and low beam driving lights, our stylishhead/turn combination light is “E” marked andapproved for all road applications.

LED Lights Indicator and Signal lights are designed implementingLED technology instead of traditionally usedincandescent lighting. The LED technology extendsthe life of the light and emits brilliant color againstEMI/RFI. The LED light also is very cost effective asthere is no risk of a filament breaking in highvibration conditions. LED signal lights are nowavailable in amber, red or blue for off-highway andconstruction equipment. Life expectancy has beenextended to approximately 25,000 hours, a greaterthan 25X improvement over traditional incandescenttechnology. The light is designed with the lens sonicwelded to the housing for 100% sealing.

StrobesRotating Beacons use a halogen bulb on a rotatingbase. Strobes are warning beacons, which useelectronics to emit light using a gas tube. As with our other lights, the beacons and strobes aredesigned to withstand high vibration conditions.

LED Indicator Lights

LED Signal Lights

Strobe and Rotating Beacon

Shock Resistant Lights Head/Turn Lights


LIGHTS

Operating Temperature -30°C to +50°C -30°C to +50°C -40°C to +85°C -40°C to +85°C -40°C to +85°C -40°C to +85°C -40°C to +85°C -40°C to +65°C -40°C to +85°CStorage Temperature -55°C to +85°C -55°C to +85°C -55°C to +85°C -55°C to +85°C -55°C to +85°C -55°C to +85°C -55°C to +85°C -55°C to +85°C -55°C to +85°C EMI/RFI ISO 13766 — — Class B Region II Class B Region II Class B Region II — Class B Region II —Environmentally Sealed to: — — — 35 kPa 35 kPa +/-35 kPa — +/-35 kPa +/-20.6 kPa


InputsSupply Voltage 12V/24V 10V to 32V 12V/24V 12V/24V 18V to 32V 18V to 32V 12V/24V 18V to 32V 12V/24VSupply Current 4.7 A/3.4 A 1.3 A 30 mA/15 mA 5.4 A/2.7 A 250 mA 350 mA 4.7 A/2.4 A 3.5 A 4.7 A/3.4 AChemical CompatibilityDiesel Fuel Yes Yes Yes Yes Yes Yes Yes Yes YesWater Yes Yes Yes Yes Yes Yes Yes Yes YesEngine Oil Yes Yes Yes Yes Yes Yes Yes Yes YesEthylene Glycol Yes Yes Yes Yes Yes Yes Yes Yes Yes

Operating Specifications

Rotating Beacon Strobes LED Indicator Combination LED Combination LED Signal 3x3 Halogen HID Flood Shock ResistantLights Head/Turn Light Rear Signals Lights Flood Lights Lights Lights

Rotating Beacon Strobes LED Indicator Combination LED Combination LED Signal 3x3 Halogen HID Flood Shock ResistantLights Head/Turn Light Rear Signals Lights Flood Lights Lights Lights


ELECTRICAL COMPONENTS

Caterpillar takes great pride in offering electrical components designed to

withstand the harshest environments—and

they’re tested to do so in our own facilities. The components operate

successfully in extreme conditions such as in the cold of Antarctica and

the heat of the Arabian Peninsula.

Our durable line of sensors and connectors are suitable to many

applications such as petroleum, waste and refuse, material handling

and agriculture.

www.catelectronics.com

SENSORS

Hall Effect ActiveSpeed Sensor

Integral ConnectorPressure Sensor

High Pressure PWM Sensor

Fuel Level Sensor

Active Temperature Sensor

Medium Duty Rotary Position Sensor

Caterpillar offers a robust and durable family ofsensors for industrial, off-highway, diesel and engineapplications. Our product line includes sensor typessuch as liquid level sensors, pulse width modulatedpressure sensors, active speed sensors, high accuracyspeed timing sensors, position sensors andtemperature sensors.

Our sensor offerings include:

Liquid Level SensorsFuel Level Sensors

Position SensorsCylinder Position SensorsHeavy Duty Rotary Position SensorsMedium Duty Rotary Position Sensors

Pressure SensorsHigh Pressure PWM SensorsIntegral Connector Pressure SensorsWire Leaded PWM Pressure Sensors

Speed/Timing SensorsHall Effect Active Speed SensorsHigh Accuracy Timing SensorsLow Speed Timing Sensors

Temperature SensorsPWM Exhaust Gas Temperature SensorsPWM Temperature SensorsActive Temperature SensorsPassive Temperature Sensors

Emissions SensorsExhaust Gas Thermocouples

Sensor SwitchesFilter By-Pass SwitchRobust Arm Bar SwitchLiquid Level Switch

44

Electronics Product Directory

SENSORS

45

Liquid Level Switch Filter By-Pass Switch Robust Arm Bar Switch

InputsSupply VoltageSupply CurrentProof PressureBurst PressurePressure RangeOutputsOutput SignalMin Surface SpeedSensing Range ResistanceInductanceResolution (Short-Tall Tank)Response to Step input change(10% to 90% of full scale step)Total Error Band

Max Sink CurrentMax Source CurrentShort to Ground or Vs Protection


18V-32V 8V-32V 5V +/- .25V 8V +/- .25V 8V-14V —80 mA 35 mA 20 mA max 20 mA max 30 mA max —

— 2X 2X 2X — —— 3X 3X 3X — —— 3000 kPaG to 70 MPaG 116 kPaA to 6394 kPaA 197 kPaA to 1135 kPaA — —

PWM-500 Hz PWM-500 Hz Analog PWM-500 Hz 0-15 kHz Max 40 kHz Typ— — — — — 0.38 m/sec Typ

305-2286 mm — — — — —— — — — — 140 Ohms— — — — — 55 mH @ 1000 Hz

12.7- 25.4 mm — — — — —— 15 ms 15 ms 15 ms — —

— +/-3% of max pres. +/-3% of max pres. +/-3% of max pres. — —(-40°C to +125°C) (-40°C to +125°C) (-40°C to +125°C)

— 20 mA 1.5 mA 1.5 mA 7.25 mA —— 20 mA 1.5 mA 1.5 mA 7.25 mA —Yes Yes Yes Yes Yes —

Fuel High Pressure Integral Wire Leaded Hall Effect High AccuracyLevel PWM Connector PWM Active Timing

Sensor Pressure Sensor Pressure Sensor Pressure Sensors Speed Sensors Sensors

Operating Temperature Storage TemperatureVibration EMI/RFISealing

EnvironmentalSpecifications

Fuel High Pressure Integral Wire Leaded Hall Effect High AccuracyLevel PWM Connector PWM Active Timing

Sensor Pressure Sensor Pressure Sensor Pressure Sensors Speed Sensors Sensors

-40°C to +125°C -40°C to +110°C -40°C to +125°C -40°C to +125°C -40°C to +120°C -40°C to +150°C-60°C to +58°C -55°C to +135°C -55°C to +135°C -55°C to +135°C -55°C to +150°C -55°C to +150°C

10 G rms (18-2 kHz) 26 G rms (20-2 kHz) 26 G rms (20-2 kHz) 26 G rms (20-2 kHz) 20 G rms (20-2 kHz) 20 G rms (20-2 kHz)100 V/m Radiated 100 V/m 100 V/m 100 V/m 100 V/m —

+/-35 kPa +/-35 kPa +/-35 kPa +/-35 kPa +/-35 kPa +/-35 kPa


SENSORS

InputsSupply VoltageLoad CurrentResponse Time from 10% to 90%of a Temperature ChangeSensed TemperatureOutputsOutput SignalMin Surface SpeedFrequencyOutput RangeResistanceInductance


— 8V +/- .25V — 8V or 24V 5V-8V —— 20 mA max — 3 mA 3 mA 10 mA

— <60s <25s <20s <60s <15s

— -40°C to +1095°C -40°C to +1095°C -60°C to +120°C -40°C to +120°C -50°C to +150°C

Max 15 kHz Typ PWM Type K Thermocouple PWM Active Analog Voltage Variable Resistance0.25 m/sec Typ — — — — —

— 500 MHz — 500 MHz or 5 kHz — —— 20 to 80% duty cycle — 9 to 90% duty cycle 0.2 to 4.5V —

1056 Ohms — — — — 1000 Ohms @25°C420 mH @1000 Hz — — — — —

Low Speed PWM Exhaust Exhaust PWMTiming Gas Temperature Gas Temperature

Sensors Sensors Thermocouples Sensors Active Passive

Low Speed PWM Exhaust Exhaust PWMTiming Gas Temperature Gas Temperature

Sensors Sensors Thermocouples Sensors Active Passive

Temperature Sensors

Operating Temperature Storage TemperatureVibration EMI/RFI

Sealing

-40°C to +150°C -40°C to +1095°C -40°C to +1095°C -60°C to +120°C -40°C to +120°C -50°C to +150°C-55°C to +150°C -55°C to +125°C -55°C to +125°C -55°C to +125°C -55°C to +125°C -55°C to +150°C

20 G rms (20 to 2 kHz) 20 G rms (20 to 2 kHz) 10 G rms (20 to 2 kHz) 20 G rms (20 to 2 kHz) 20 G rms (20 to 2 kHz) 20 G rms (20 to 2 kHz)— 100 V/m 100 V/m 100 V/m 100 V/m —

+/-35 kPa +/-35 kPa +/-35 kPa 35 kPa (housing), 35 kPa (housing), 35 kPa (housing), 1000 kPa (probe) 1000 kPa (probe) 1000 kPa (probe)


Temperature Sensors


SENSORS


10V +1/-3V 10V +1/-3V 18V-32V 9V-32V or 8V100 mA max 100 mA max 40 mA max 30 mA max

— — 140 and 120 deg. 72, 102, & 310 deg.

PWM PWM PWM PWM500 Hz +/-100 Hz 115 Hz +/-15 Hz 350-700 Hz 350-700 Hz

< 1.0V < 1.0V < 1.0V @ 9 mA sink < 5.0V @ 8 mA sink> 3.9V > 3.9V — >4.0V @ 1.0 mA source

Yes Yes — —

2000 mm/s 2000 mm/s — —< 1.5 X resolution < .12 X resolution 2% 1% for sensors with

+0.6 mm +0.004% or 0.15 mm spring return<4 mm @ 1 MHz, <0.5 mm @ 1 MHz, — —

and <1 mm @ 5 MHz and <0.1 mm @ 5 MHz

+/-0.1% of full stroke +/-0.05% of full stroke — —or +/- resolution or +/- resolution

50 mm to 1200 mm 50 mm to 2000 mm — —2 million strokes 2 million strokes 3 million cycles 10 million cycles

— — 10 mA 9 mA— — +/- 2.0% Full scale +/- 2.5% Full scaleYes Yes Yes Yes

InputsSupply Voltage Supply CurrentAngular RangeOutputsOutput SignalFrequencyOutput Low (Sink)Output High (Source)Output (PWM) V (low) maximum<1.0Vand V (high) minimum >3.9V Maximum Velocity

Hysteresis

Resolution

Position Accuracy

Displacement RangeSensor LifeMax Sink CurrentLinearityShort to Ground or Vs Protection

Cylinder Position Sensor Rotary Position Sensor

Class 3 Class 2 Heavy Duty Medium Duty

Class 3 Class 2 Heavy Duty Medium Duty


Operating TemperatureStorage Temperature VibrationEMI/RFIStop StrengthActuation ForceAxial LoadRadial LoadHydraulic Pressure Limits:Continuous/Transient

Sealing

-40°C to +120°C -40°C to +120°C -40°C to +85°C -40°C to +85°C-55°C to +150°C -55°C to +150°C -55°C to +85°C -55°C to +85°C

15.3 G rms (20 to 2 kHz) 15.3 G rms (20 to 2 kHz) 20 G rms (24 to 2 kHz) 15.3 G rms (24 to 2 kHz)100 V/m 100 V/m 100 V/m Rad Immunity 100 V/m Rad Immunity

— — 60 Nm —— — 1 Nm —— — 1000 N max —— — 1000 N max —

41,358 kPa / 82,717 kPa 41,358 kPa / 82,717 kPa — —

— — +/-35 kPa +/-25 kPa when mountedper specifications

Cylinder Position Sensor Rotary Position Sensor


SENSORS

Filter Robust LiquidBy-Pass Arm Bar LevelSwitch Switch Switch

Filter Robust LiquidBy-Pass Switch Arm Bar Switch Level Switch

12V-24V 12V-24V —— 100V max —— — —

0.5 A 0.5 A —100 mV @ 2.5 mA max — 100 mV @ 2.5 mA max

— — 5V-28V

Switch to Ground Switch to Ground —— — —

Single Single SingleSingle Double Single

10,000 cycles 50,000 cycles 100,000 cycles— — 100 mA @ 28V— — Yes— — Yes— — Yes

N/C side of contact — N/C side of contact— — Common

0.1 A — —0.1 A — —0.1 A — —


InputsSupply VoltageSwitching VoltageLeakage CurrentContact RatingVoltage DropVoltage ActuationOutputsOutput SignalProtectionMechanicalNumber of PolesNumber of ThrowsLifeContact ConfigurationMedium (Hydraulic oil)Medium (Lubricant)Medium (Ethanol)SchematicsPin 1Pin 2Max LoadResistiveInductiveLamp

Standard Spec’s

Protection

Vibration

Storage TemperatureOperating TemperatureMountingSealing10 G, 18 to 500 Hz15.3 G, 24 to 2000 Hz10 G, 20 to 2000 Hz

Environmental Specifications— — —

-40°C to +121°C -40°C to +85°C -40°C to +125°C— — —

35 kPa 10.34 kPa Impervious to oil, fuel, salt— — Yes— Yes —Yes — —


ConnectorsThe Caterpillar Connector Series is a heavy-dutyplastic electrical connection system for use withinline, bulkhead and device applications. Applicationsinclude wire to wire and wire to PC applications. Thesealing plugs can be molded into the plug connectors’wire seal cover. Bulkhead connectors are available inmultiple sizes along with a wire dress cover providingwire seal protection from pressure wash spray.

Environmental SpecificationsOperating Temperature -40°C to +120°CFluid Compatibility Diesel fuel, brake fluid, engine oil, engine coolantSealing Environmentally sealed to 1 m of water (mated pair plug & receptacle)

14 AWG (SXL) – 18 AWG(GXL) PC board connector sealed to 35 kPa through the pins

Operating Characteristics/SpecificationsCurrent Rating: 13 amps per terminal*

Wire Range: 14-18 AWG

Mechanical:

Keying: 6 key ways plus a universalMating: Jackscrew mating; M6 thread with M4 Allen headConnector Sizes Available: 26, 70 & 120 position (plug & receptacle; standard length PC pins)

34 & 48 position (header only; long PC pins)* Consult Caterpillar for maximum total current carrying capability and application assistance

CONNECTORS

Connectors

Proven Experience For about 30 years, Caterpillar has been

providing real-world electronic and

electrical solutions for the markets we

serve. From on-highway to mining,

construction to electric power, marine to

agriculture, Caterpillar offers value-added

electronic solutions that stand up to the

world’s harshest environments. With annual

shipments of more than 300,000 controls,

14-million components and production

software, Caterpillar is not just an iron

company, Caterpillar is a world-class

electronics company.

Headquartered in Mossville, Illinois,

Caterpillar’s Electronic and Electrical

Systems division has six facilities

worldwide with over 35,000 square feet of

lab space. It is at these state-of-the-art

facilities that new industry standards are

being established. The division has over

700 engineers, professionals and

technicians whose work in their field of

expertise continues to integrate new

technology throughout our product line.

This broad experience and understanding

of heavy-duty application environments—

like severe vibration, shock, extreme

operating temperature ranges, thermal

cycle, thermal shock, humidity, corrosion

and excessive dust—has resulted in several

hundred U.S. and foreign patents in

components, software features and

algorithms.

Caterpillar offers a total solution for custom

electronic control systems, electrical and

operator interface components and asset

management tools. Our custom solutions

enable Tier 1 suppliers and OEMs to

provide a powerful point of differentiation

in the heavy-duty industries they serve.

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