Electronics from Caterpillar

Caterpillar Inc. is more than big, heavy equipmentand 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. Caterpillars 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 productsthis 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 catelectronics@cat.com

Electronic Components Controller Software Integrated Systems

Our Vision
We will be the global leader in providing motion and power control solutions.

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TABLE OF CONTENTS
Electronic Control Modules
A4:E1 A4:E2 A4:E4 Machine Controllers . . . . . . . . . . . . . . . . . . . 8-9 A4:M1 A4:M3 A5:M2 Communications Controllers. . . . . . . . . . 10-11 A4:N1 A4:N2

page

Tactile Operator Interface

Handles Joysticks Levers Shifters

page

Electrical Components
Fuel Level Sensor

page

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

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

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

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

Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Rocker Switch Electronic Key Switch Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Silicone Spring Block Compression Spring Governor Pedal

Asset Management
Machine Security System . . . . . . . . . . . . 14-15 Electronic Service Tools . . . . . . . . . . . . . 16-17

Seating
Comfort Seat . . . . . . . . . . . . . . . . . . . . . . . . 36-37

Cylinder Position Sensors Rotary Position Sensors Filter By-Pass Switch

Visual Operator Interface

Data 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

Lighting
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Robust Arm Bar Switch Liquid Level Switch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Electronics Product Directory

ELECTRONIC CONTROL UNITS

Our Controllers have been developed for todays robust applications. They are capable of advanced

control and diagnostics. configurable and

This is the most comprehensive line of versatile,

rugged controllers in use around the world today.

Cat Electronic Control Units offer powerful capabilities for use in many mobile OEM and industrial applications.

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Electronics Product Directory

A4 ENGINE CONTROLLERS
A4:E1 Controllers
The A4:E1 controller line offers unsurpassed versatility. Using Power PC technology, this controller can be programmed for applications as varied as implement control and as an intelligent remote I/O module.
A4:E1 Controller

A4:E2 Controllers
The A4:E2 range of controllers has been developed for the advanced control requirements. Using Power PC technology, the A4:E2 is capable of advanced control and diagnostics.

A4:E2 Controller

A4:E4 Controllers
Our range of A4:E4 controllers has been developed with tomorrows requirements in mind. Using the latest Power PC technology for advanced high speed processing, this range of controllers is capable of advanced control and diagnostics.

A4:E4 Controller

Environmental Specifications
Operating Temperature Range - Fuel Cooled - Air Cooled Fuel Temperature* Fuel Flow Rate* Radiated Immunity Storage Temperature Range (normal) Output Short Circuit Tolerance Input Short Circuit Tolerance Humidity Tolerance Salt Spray Tolerance Chemical Splash Immunity Vibration (shock isolated components tolerance) Moisture Leakage (sealant pressure tolerance) Electrostatic Environment *Fuel Cooled housing only

A4:E1, A4:E2 & A4:E4

-40C to +110C -40C to +85C 80C 2.5 L/min (max) 15.0 kHz to 1.0 GHz @100 V/M -50C to +120C 75% to 133% (NSV) Nominal System Voltage Between Input and Batt+/Batt115% NSV, 90% relative humidity over operating temperature range 115% NSV with 5% salt spray for 48 hours at 35C Diesel fuel, engine/machine oil & SAE J1455 chemical agents 8.00 G rms random vibration from 24-2000 Hz in three orthogonal planes +/- 35 kPa against water and water vapor Zero damage during exposure to electrostatic painting process

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A4 ENGINE CONTROLLERS
Operating Characteristics/ Specifications
Standard Housing Air Cooled Fuel Cooled Military Housing Inputs Switch to Ground Switch 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 mA 2-Wire Hall Effect Inputs System Voltage Input Voltage Sensor Power Supplies Analog 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

A4:E1

A4:E2

A4:E4FF

A4:E4HD

A4:E4IE

Yes No No 12 2 1 4 3 1 2 12V/24V 1 1 3 1 (50 mA) 1 (1.0 A) 3 (2.0 A)

Yes Yes No 11 2 1 8 5 1 1 2 12V/24V 1 1 2

Yes Yes Yes 17 2 1 10 4 10 5 8 1 2 12V/24V 1 1 1 1 3 5 (2.0 A) 3 (2.0 A/PWM) 2 (3.0 A) 4 (300 mA/PWM) 1 (2.0 A) 3 (2.5 A) 1 (3.75 A) 2 2 12 8 MPC561 56 MHz 2 MB 256 KB 8 KB

Yes No No 17 2 1 5 3 5 4 2 12V 1 1 1 2 5 (2.0 A) 3 (2.0 A/PWM) 2 (3.0 A) 4 (300 mA/PWM)

Yes Yes No 17 2 1 10 4 5 5 6 1 12V/24V 1 1 1 2 5 (2.0 A) 3 (2.0 A/PWM) 2 (3.0 A) 4 (300 mA/PWM) 1 (2.0 A) 3 (2.5 A) 2 6 4 MPC561 56 MHz 2 MB 256 KB 8 KB

10 (300 mA) 1 (1.0 A) 2 6 MPC561 56 MHz 2 MB 256 KB 32 KB

On/Off Sinking Drivers PWM Current Drivers Analog 4-20 mA Driver Frequency Drivers (Speedo/Tacho) Injector Drivers (high sides) Injector Returns (low sides) Processing Elements Microprocessor Processor Speed Flash ROM SRAM EEPROM

8 (12V 300 mA) 6 (12/24V 300 mA) 2 MPC555 40 MHz 448 KB 256 KB 32 KB

2 6 4 MPC561 56 MHz 2 MB 256 KB 8 KB

Electronics Product Directory

A4 & A5 MACHINE CONTROLLERS

A4:M1 and A4:M3 Controllers
Our range of machine controllers has been developed around our high-speed Power PC technology to offer a configurable, rugged controller capable of use in a wide range of applications. With a high density of built-in I/O and capable of master/slave communication, the A4:M1 and A4:M3 can be used as a stand-alone controller or in a system. These controllers are available in our standard and military housings for even more rugged applications and EMC sensitive systems.

A4:M1 Controller

A5:M2 Electronic Control Module

The A5:M2 electronic control module is an electronic hydraulic (EH) control module, but it can function as a general-purpose control capable of fitting into varied applications by simply changing the software application level. A key feature of this unit is the ability to configure the inputs and outputs in many different combinations.

A4:M3 Controller

A5:M2 Controller

Environmental Specifications
Operating Temperature Range System Voltage Radiated Immunity Storage Temperature Range (normal) Output Short Circuit Tolerance Input Short Circuit Tolerance Humidity Tolerance Salt Spray Tolerance Chemical Splash Immunity Vibration (shock isolated components tolerance) Moisture Leakage (sealant pressure tolerance) Electrostatic Environment

A4 & A5
-40C to +85C 12V/24V 15.0 kHz to 1.0 GHz @100 V/M -50C to +120C 75% to 133% (NSV) Nominal System Voltage Between Input and Batt+/Batt115% NSV, 90% relative humidity over operating temperature range 115% NSV with 5% salt spray for 48 hours at 35C Diesel fuel, engine/machine oil & SAE J1455 chemical agents 8.00 G rms random vibration from 24-2000 Hz in three orthogonal planes +/- 35 kPa against water and water vapor Zero damage during exposure to electrostatic painting process

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A4 & A5 MACHINE CONTROLLERS

Operating Characteristics/ Specifications

Standard Housing Air Cooled Military Housing Inputs Switch to Ground Switch to Battery (+Bat) Config. Switch to Ground/Switch to Battery Key Switch (+Bat) Neutral Start Input Analog Input (Active) Analog Input (Passive) Prog. Analog Input (Active/Passive) PWM / Frequency Input / Switch to Ground PWM Input (High Accuracy) Speed Input (Passive)* Programmable 5V/8V Sensor Supply @ 330 mA Battery Monitor R-Terminal Input Sensor Power Supplies 5V Sensor Supply (200 mA) 8V Sensor Supply (400 mA) 10V Sensor Supply (3 A) Communication Links CAN Data Link ATA Outputs On/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 Elements Microprocessor Processor Speed Flash ROM SRAM EEPROM * For single-ended inputs, one line is left open. ** Can be separated into 16 individual on/off drivers.

A4:M1

A4:M3

A5:M2

Yes Yes 35 3 1 1 2 4 16 4 6 1 1 1 1 1 2 1 6 8 10 2 MPC555 40 MHz 2 MB 256 KB 32 KB

Yes Yes 25 1 1 2 3 11 4 1 1 1 1 1 4 8 8 MPC555 40 MHz 2 MB 256 KB 32 KB

Yes No 6 1 8 6 4 2 1 2 1 4 8** MAC 7131 40 MHz 512 KB 160 KB 32 KB

Electronics Product Directory

COMMUNICATIONS ELECTRONIC CONTROL UNITS

Electronic Control Units
These modules enable network access to information and operating parameters. The ECUs have communications architecture that can replace many of todays purpose-built applications and provide almost limitless possibilities for future applications.

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)

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COMMUNICATIONS ELECTRONIC CONTROL UNITS

Environmental Specifications
Operating Temperature Range (ambient) Storage Temperature Range (Normal) Radiated Immunity Output Short Circuit Tolerance Input Short Circuit Tolerance Humidity Tolerance Salt Spray Tolerance Chemical Splash Immunity Vibration (shock isolated components tolerance) Moisture leakage (Sealant pressure tolerance) Electrostatic environment

A4:N1, A4:N2
A4:N1, -40C to +85C A4:N2, -40C to +75C -50C to +120C 15.0 kHz to 1.0 GHz @ 100 V/M 75% to 133% (NSV) Nominal System Voltage Between Input and Batt+ / Batt115% NSV, 90% relative humidity over operating temperature range 115% NSV with 5% salt spray for 48 hours at 35C Diesel fuel, engine/machine oil & SAE J1455 chemical agents 9.80 G rms random vibration from 24-2000 Hz in three orthogonal planes +/- 35 kPa against water and water vapor Zero damage during exposure to electrostatic painting process

Operating Characteristics/ Specifications

External Power Supply 8V Sensor Power Supply (optional) Communication J1708 (ATA) Data Link or (CDL) CAN 2.0 Data Link J1939 CAN Data Link RS-232 Serial ports (1 w/ DTR, DCD) RS-485/422 Ethernet Processing and Memory MPC561 Microprocessor MPC555 Microprocessor Flash ROM SRAM BBRAM EEPROM Real-Time Clock Inputs Switch to Battery wake up input Key Switch (+Bat) PWM/Frequency/Switch to Ground Inputs Analog Input Alternator R-Terminal Input Outputs On/Off Sinking driver (300 mA)

A4:N1

A4:N2

1 1 2 3 1 56 MHz 4 MB 4 MB Max. 2 MB Max. 32 KB Max. 1 1 1 14 2 1 4

1 1 2 3 (1 Opto Isolated) 1 (1 Opto Isolated) 1 40 MHz 4 MB 4 MB Max. 2 MB Max. 32 KB Max. 1 1 1 6 4

Electronics Product Directory

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ASSET MANAGEMENT

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Caterpillar has developed powerful tools for you to

track the performance, location and service intervals of your fleet in any
environment. The Electronic Service Tool enables service technicians to assess a machines performance and health from any system quickly and accurately. This onsite evaluation may help reduce a machines downtime and improve

the

safety 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.

Electronics Product Directory

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MACHINE SECURITY SYSTEM (MSS)

Stolen equipment is lost productivity. Protect your equipment against theft by installing the Cat Machine Security System. Other systems promote the ability to track stolen equipment, but that doesnt prevent thievery and the subsequent production loss. Dont waste your time recovering equipment. Stop machine theft upfront with Machine Security System. The Cat system protects nearly all brands of equipment, regardless of time or location. It guards against theft by disabling a machines starting system. Thieves cannot bypass the starting system because Machine Security System is integrated into the electronics. Only a key with your unique code can start 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 Works

Each Machine Security System key contains a unique identification number. The machine electronic control module checks the key being inserted against a pre-approved list of keys you have authorized. If the key is on the list, the machine will start. This method is superior to much simpler add-on theft deterrent devices. Its sophisticated design is integrated into the electronics of the machine, making it virtually impossible to defeat.

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MACHINE SECURITY SYSTEM (MSS)

Controlling Machine Access
Machine Security System has programmable features to 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 or unauthorized personnel, reducing injury risk MACHINE SECURITY SYSTEM KEY Programmable for active and inactive periods, such as disarming the system during regular work hours when a standard key can be used and then reverting to a DASH LIGHT ENGINE OR TRANSMISSION security key after hours ELECTRONIC CONTROL Programmable so a key will expire on a certain MODULE date 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 unique identification number The security keys are either yellow or gray, while standard keys are black This Cat theft deterrent system can be programmed so one key can operate any machine in your fleet A machine can be programmed to accept up to 255 unique security keys MACHINE SECURITY SYSTEM ELECTRONIC CONTROL MODULE

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

Electronics Product Directory

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ELECTRONIC SERVICE TOOLS

Electronic Service Tool
The PC-based service tools from Caterpillar provide the capability to access Electronic Control Modules (ECMs) from a personal computer. Many job-critical tasks can be performed with an electronic service tool. The user can display the status of a group of parameters (temperatures, pressures, etc.) simultaneously, view active and clear logged diagnostics, display the current configuration of an ECM and much more. The service tool works with a communication adapter to allow connection to an ECM. A graphical interface makes this software quick to learn and easy to use. A separate pull-down menu for each function enhances the ease of use. The version and identification of the ECM is automatically retrieved and is displayed on a summary screen when the program is started. Diagnostic tests and calibrations can also be performed. Caterpillar PC-based tools enable service technicians to reprogram ECMs, reconfigure control system parameters, fine tune performance or diagnose the root cause of a failure the first time. These powerful tools allow service personnel to display and analyze vital performance and health information from any system quickly and accurately. The service tool communicates with any system using ATA (J1708), J1939 or the Caterpillar proprietary data link networks. The service tools provide information and features needed to help a technician diagnose problems and perform repairs and to customize and personalize the operation of a product. By allowing customers to design flexibility and configurability into a product, Caterpillar service tools stretch beyond the capabilities of preprogrammed ECMs or onboard display systems.

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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 have occurred and have been logged by the ECM. Perform calibrations to enhance performance of the ECM. Customize the ECM with application-specific settings. Over 100 custom Diagnostic, Information and Service 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 another customer. Licensing options for customer management Flash programming of the ECM(s) Training demonstration allows familiarity with the tools primary functions without connecting to ECM(s) Major operating systems support (Microsoft Windows 95, 98, NT 4.0, 2000, ME, & XP) Perform customized diagnostic tests to identify harness problems, cylinder or component failures (Automatic Cylinder Cutout with cylinder to cylinder fueling comparison)

Electronics Product Directory

17

VISUAL OPERATOR INTERFACE

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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.

Electronics Product Directory

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DATA LINK GAUGES AND GAUGE CONTROLLER

Data Link Gauges
This SAE J1939 Data Link system is composed of digitally controlled analog-style gauges that combine the accuracy and dependability of electronics with the simplicity and visual clarity of conventional analog gauges. The system is designed for plug and play installation on various applications in many harsh environments including waste and refuse, petroleum, material handling, agricultural and fire and rescue.

Gauge Controller
The Gauge Controller receives, translates and resends the J1939 information via a local data link to the appropriate gauge while providing a single interface to the data link for the gauge system. The user can mount the controller on the rear of any 3" gauge or in a separate location if the panel location does not allow space for the gauge controller and harnessing to be attached.

Data Link Gauges

Operating Characteristics/ Specifications

Features Auxiliary Pressure (0 -3447 kPa) Auxiliary Temperature (-40C to 49C) Backlighting (Switch to battery input) Boost Pressure (0-345 kPa) Engine Coolant (-18C to 120C) Exhaust Temperature (49C to 872C) Fuel Level (0 - 4/4) Fuel Pressure (0 - 862 kPa) Fuel Rate (0 - 757 lph) Fuel Temp (-18C to 120C) Inlet Manifold Temp (-18C to 120C) LCD Display Oil Pressure (0 - 689 kPa) Oil Temperature (-18C to 120C) 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 (-18C to 120C) Volt

Data Link Gauges

2" Gauge Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 0V-32V 3" Gauge Yes Yes Yes Yes Yes Yes Yes Yes Vehicle or Engine Hours Yes Yes Yes Yes Yes Yes Yes 9V-32V

Gauge Controller

Environmental Specifications
Operating Temperature Range -40C to +85C Storage Temperature Range -55C to +85C Vibration 9.8 G rms random vibration from 24 Hz to 2000 Hz Seal Sealed to +/- 35 kPa against water and water vapor Output Short Circuit Tolerance 75% to 133% (NSV) Nominal System Voltage Input Short Circuit Tolerance Between Input and Batt+ 115% NSV, 90% relative humidity over Humidity Tolerance operating temperature range Salt Spray Tolerance 115% NSV with 5% salt spray for 48 hours at 35C Chemical Splash Immunity Diesel fuel, engine/machine oil & SAE J1455 chemical agents Electrostatic Environment Zero damage during exposure to electrostatic painting process

Operating Characteristics/ Specifications

Gauge Controller
9V-32V 9V-18V 1 1

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Supply Voltage: Gauge Controller Operating Supply Voltage Range (+Bat Input) Gauge Operating Supply Voltage (Supplied by Gauge Controller) Communication: J1939 CAN Data Link Gauge Data Link

INSTRUMENT CLUSTERS
Instrument Clusters
D1:G9.5 D1:G1.3 D1:G9.3

Caterpillar has designed instrument clusters with robust features to endure the cold, heat and humidity of todays harsh work environments. Communicating on the SAE J1939 data link, the clusters are able to provide critical operating information to the user while the machine or engine is in use, 24 hours a day, seven days a week. The clusters include LED indicator lights, LCD digital displays and backlighting.

D1:G9.1

Environmental Specifications
Operating Temperature -20C to +70C -40C to +85C Storage Temperature -40C to +85C -20C to +75C Vibration 9.8 G 24-2000 Hz Sealing/Protection Sealed to IP65 Front, IP52 Rear Sealed to IP65 Front and Rear Sealed to IP66 Front, IP52 Rear

D1:G9.5 Gen II Cluster

D1:G9.3 CIC Cluster

D1:G9.1 SSL Cluster

D1:G1.3 CWL Cluster

Yes Yes Yes

Yes Yes Yes Yes

Yes Yes Yes Yes

Yes Yes Yes Yes

Yes

Operating Characteristics/ Specifications

Inputs/Outputs Generic Switch to Battery Keyswitch Input Output Horn Driver Communication Data Links Electrical Power Supply Physical Characteristics Dimensions Weight Mounting Type Monochrome Transflective LCD Display LED Indicators Backlighting Connectors 35 pin environmentally sealed (Ampseal) 12 pin environmentally sealed integral DT 24 pin environmentally sealed integral DT

D1:G9.5 Gen II Cluster

D1:G9.3 CIC Cluster

D1:G9.1 SSL Cluster

D1:G1.3 CWL Cluster

4 1 1 1 9V-32V LCD 110 mm x 40 mm 1.51 kg Panel Yes 18 White Yes

1 1 1 1 9V-32V LCD 110 mm x 40 mm Panel Yes 12 Amber Yes

1 1 1 9V-18V LCD 89 mm x 25 mm Panel Yes 16 (Basic) Red Yes

1 1 1 9V-32V LCD 55 mm x 39 mm Panel Yes (Interactive) 17 Red Yes 21

Electronics Product Directory

DISPLAYS
Advisor
Advisor 6.0m2 is a monochrome, LCD graphical information display capable of displaying real time operating information on parameters such as RPM speed and fuel consumption, and is targeted for use in heavy-duty operating conditions. The displayed data can be obtained from an existing data link that connects engines, transmissions and hydraulic systems.

D3:M3 Advisor Display Unit

Messenger
The Messenger operator information display provides real-time visual feedback on operating conditions to help ensure the best performance possible from your equipment. Messenger uses a full graphics information display with transflective LCD technology. Multiple communication data links can be utilized to provide realtime performance and operating information while the equipment is in use. The information can be displayed in either multilingual text (even graphical languages) or a graphical format.

D3:M2 Messenger Display Unit

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

D3:C4 HD Monitor Display

Environmental Specifications
Operating Temperature -20C to 70C -40C to 85C -20C to 75C -40C to 85C -50C to 85C 4.3 G 24-2000 Hz 9.8 G 24-2000Hz Sealed to +/- 35 kPaG case, IP68/NEMA 13

D3:M3 Advisor 6.0m2 Yes Yes Yes Yes

D3:M2 Messenger Yes Yes Yes Yes

D3:C4 HD Monitor Display Yes Yes Yes Yes

Storage Temperature Range

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DISPLAYS
Screen Builder Tool
Screen Builder Tool is a Windows-based tool for screen layouts. You can choose from a variety of offerings of graphics for multiple screen layouts for each application. Screen builder software is compatible with Windows 95/98/NT 4.0, Windows 2000 PC operating systems and is J1939 compatible.

Operating Characteristics/ Specifications

Inputs/Outputs Generic Switch to Battery Keyswitch Input Output Horn Driver High Side Drivers PWM Switch to Ground Analog Voltage Switch to Ground R-terminal Alternator Input PWM Inputs Communication RS 232 Data Links Processing Elements Processor RAM/SRAM Flash Memory EEPROM Screen Builder Tool Electrical Power Supply 10 +/- 1V Supply (Output) 5V Regulated Supply (Output) Physical Characteristics Dimensions Weight Mounting Type Monochrome Transflective LCD Display LED Indicators Backlighting Buttons Approvals Connectors 70 pin environmentally sealed 8 pin environmentally sealed integral DT 12 pin environmentally sealed integral DT

D3:M3 Advisor 6.0m2

D3:M2 Messenger

D3:C4 HD Monitor Display

1 1 2 8 4 1 1 3 68376 Mot. 32 bit @ 24 MHz 2 MB 1 MB 32 KB Yes 9V-32V Yes Yes 71 x 140 x 221 mm 1.59 kg Panel/Gimbal Yes Yes White 10

1 1 3 68376 Mot. 32 bit @ 24 MHz 512 KB 1 MB 32 KB Yes 9V-32V

1 1 2 32 KB 512 KB 32 KB Yes 9V-32V

60.5 x 66 x 119.5 mm 147.9 x 228.6 x 47.65 mm 0.27 kg 1.81 kg Panel/Gimbal Panel/Gimbal Yes Yes Red White/Red 4 4 CE, BV, DNV, LR, CE G2, ABS Yes Yes

Yes

Electronics Product Directory

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ALARM HORN AND HOURMETER

Alarm Horn and Hourmeter
The Hourmeter allows an operator to determine the hours spent on a machine or engine. The Alarm Horn alerts an operator of an active diagnostic condition or event on a machine or engine. The J1939 CAN Data Link Communication provides the ability of the Hourmeter and Horn to receive information from various ECUs or controller modules.

Hourmeter

Alarm Horn

Environmental Specifications

Alarm Horn

Operating Temperature -40C to +85C Storage Temperature -55C to +85C Supply Voltage Range 9V-32V Output Short Circuit Tolerance 75% to 133% (NSV) Nominal System Voltage Humidity Tolerance 115% NSV, 90% relative humidity over operating temperature range Salt Spray 115% NSV with 5% salt spray for 48 hours at +38C Chemical Splash Diesel fuel, engine/machine oil & SAE J1455 chemical agents Vibration 9.8 G rms random vibration from 24-2000 Hz in three orthogonal planes Shock 15.0 G rms in three orthogonal planes Moisture Leakage +/-35 kPa against water and water vapor Electrostatic Environment Zero damage during exposure to electrostatic painting process Button Endurance 500,000 cycles

Operating Characteristics/ Specifications

Interfaces Electrical Power Input Data Input Connectors Functions Alarm Acknowledge Button LED Warning Indicator Horn Test External Horn Driver Horn Characteristics Frequency Sound Pressure Level

Alarm Horn

9V-32V 2 lines Deutsch DT style 6-pin integral connector Yes Self-test on start up Self-test diagnostic on power up 300 mA @ 12V/24V 2900 Hz +/-500 Hz 90-100 dB at 60 cm

Environmental Specifications

Hourmeter

Operating Temperature -40C to +85C Storage Temperature -55C to +85C 9V-32V Supply Voltage Range Output Short Circuit Tolerance 75% to 133% (NSV) Nominal System Voltage Humidity Tolerance 115% NSV, 90% relative humidity over operating temperature range Salt Spray 115% NSV with 5% salt spray for 48 hours at +38C Diesel fuel, engine/machine oil & SAE J1455 chemical agents Chemical Splash Vibration 9.8 G rms random vibration from 24-2000 Hz in three orthogonal planes 15.0 G rms in three orthogonal planes Shock +/-35 kPa against water and water vapor Moisture Leakage Electrostatic Environment Zero damage during exposure to electrostatic painting process

Operating Characteristics/ Specifications Hourmeter

Interfaces Electrical Power Input Data Input Connectors LCD Display Back Lighting Zero Delay Response Time Display Type Data Link Communication Type 9V-32V 2 lines and a shield Deutsch DT style 6-pin integral connector White or Red LED technology -20C and above Transflective, positive mode J1939 CAN

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ALARMS AND HORNS

Alarms and Horns
The Audible Alarms product line consists of three main product categoriesforward warning horns, back-up alarms and audible signal devices. The Disc Horn and Trumpet Horn are mounted at the front of the vehicle to warn of forward motion. The Fixed Level and Self-Adjusting alarms are mounted at the back of the vehicle to warn of reverse motion. SelfAdjusting alarms change sound level output according to the surrounding sound level. Our panel mount audible signal devices are piezoelectric while bracket mount devices are electromechanical.

Disc Horn

Backup Alarm

Bracket Mount Signal Device

Panel Mount Signal Device

Environmental Specifications
Operating Temperature Storage Temperature Sealing

Bracket Mount -20C to +60C -50C to +85C

Panel Mount -20C to +60C -50C to +85C

Fixed Level Alarm -20C to +60C -50C to +85C Spray Wash

Self-Adjusting Alarm -20C to +60C -50C to +85C Spray Wash

Disc Horn -20C to +60C -50C to +85C 34.5 kPa

Trumpet Horn -20C to +60C -50C to +85C

Operating Characteristics/ Specifications

Supply Voltage Supply Current Loudness Tone

Bracket Mount 12V/24V <1 A 90 dB @ 1.0 M 500 Hz

Panel Mount

Fixed Level Alarm

Self-Adjusting Alarm

Disc Horn 12V/24V 4.5 A 108 dB @ 2 M 335/400 Hz

Trumpet Horn 24V 6A 114-119 dB @ 3 M 328 Hz

12V/24V 12V/24V 12V/24V <1 A <1 A <1 A 78-92 dB @ 0.61 M 97/107/112 dB @ 1.2 M 87-112 dB @ 1.2 M 1200 Hz 1200 Hz 2900 Hz

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25

WORK AREA VISION SYSTEM

The new, versatile Caterpillar Work Area Vision System (WAVS) can provide machine operators with views from up to 3 cameras through advanced switching algorithms. While not intended to be used in place of direct views or installed mirrors, WAVS is a great asset for operators at any level. Developed specifically for rugged applications and environments, the Caterpillar Work Area Vision System is simple to install on any machine and is easy to useyet 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

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WORK AREA VISION SYSTEM

Operating Characteristics/ Specifications

System Supply Voltage Current Display Type Resolution Aspect Ratio Luminance Weight Dimensions (w/o bracket) Sealing Operating Temperature Camera Type Picture Elements Light Sensitivity Viewing Angle (degree) Standard Optional Weight Dimensions (w/bracket) Sealing Operating Temperature Switcher Type Inputs Outputs Weight Dimensions Sealing Operating Temperature Cable +11V to +32V 1.5 A max. (12V system) for 3 camera system 1.0 A max. (24V system) for 3 camera system 7" (178 mm) color TFT (Thin Film Transistor) LCD (480 x 3) x 234 pixels 16:9 400 Cd/m2 (adjustable down to 4 Cd/m2) 2.3 kg 175 mm L x 125 mm H x 70 mm D Note: 25 mm D without sun cover IP54 (withstands splash, but not immersion) -40C to +75C Color .25" (6.35 mm) CCD 512 (H) x 582 (V) 0.5 lux

WAVS

115 (H) 86 (V) 78 (H) 52 (V) 420 g 66 mm H x 77 mm W x 55 mm D IP69K, DIN-IEC 529 (withstands high pressure wash and immersion) -40C to +75C Solid state 3 (prioritized) 1 134 g 134 mm L x 36 mm W x 31 mm H IP67 -40C to +75C Video cables are available in a variety of lengths for installation on any size machine

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27

TACTILE OPERATOR INTERFACE

Electronic products from Caterpillar are designed and tested to perform in and withstand the harshest operating

environments. Our broad experience and understanding of

heavy-duty application environmentssevere vibration and shock, extreme operating temperature ranges, humidity, corrosion, excessive dusthave 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 operators environment. Our joysticks, levers, switches and pedals have all been designed to improve

the experience and

productivity for the operator.

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Electronics Product Directory

29

JOYSTICKS AND SHIFTERS

Handles, Joysticks, Levers and Shifters
Operators want their machines to look, feel, drive and ride more like their personal vehicles. The Caterpillar line of Handles, Joysticks, Levers and Shifters has been developed using highly reliable electronic components to satisfy that operator requirement. The product line is comprised of the following:
Column Mounted Shifter

Column Mounted Shifters have a five-million cycle life expectancy and two-million cycle speed capability. The reliable electronic shifters and shuttles for transmission direction and speed input are data link ready and exhibit excellent environmental performance. The Handles, Joysticks and Levers are modularly designed allowing for application customization while minimizing development time, cost and tooling. The products have a long life expectancy. The handles and joysticks are ruggedly-designed making them more reliable than other commercially-available products and the serviceable modules reduce customer costs.

Electronic Joystick

Prophet Handle

S4 Handle

S7 Handle

Single Axis Lever

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JOYSTICKS AND SHIFTERS

Environmental Specifications
Chemical Compatibility Diesel Fuel Water Engine Oil Tri-Sodium Phosphate Cleaners Operating Storage 9.8 G random, three axis 8 G rms 24-2000 Hz, three axis Meets EU requirements 100V/m radiated (15 kHz to 1 GHz) +/- 35 kPa 10.4 kPa water spray Direction Speed Integral 12 pin DT
Column Mounted Shifter Prophet Handle Electronic Joystick

Temperatures Vibration EMI/RFI Sealing Life Connector

Yes Yes Yes Yes -40C to +85C -50C to +85C Yes Yes Yes 5 million cycles 2 million cycles Yes

Yes Yes Yes Yes -40C to +85C -40C to +85C Yes Yes Yes

Yes Yes Yes Yes -40C to +85C -40C to +85C Yes Yes Yes 2.5 million cycles

Environmental Specifications
Operating Temperature Range Storage Temperature Range Vibration EMI/RFI Sealing Life Direction Connector Type Chemical Compatibility Diesel Fuel Water Engine Oil Tri-Sodium Phosphate Cleaners

S4 Handle -40C to +85C -50C to +85C 9.8 G rms, 3 axis Meets EU Requirements +/-35 kPa Button 1 million, Roller 1.5 million Deutch 12 pin Yes Yes Yes Yes

S7 Handle -40C to +85C -50C to +85C 9.8 G rms, 3 axis Meets EU Requirements +/-35 kPa Button 1 million, Roller 1.5 million Deutch 12 pin Yes Yes Yes Yes

Single Axis Lever -40C to +85C -50C to +85C 9.8 G rms, 3 axis Meets EU Requirements +/-35 kPa 6 million cycles Deutch 6 pin Yes Yes Yes Yes

Operating Characteristics/ Specifications

Inputs Supply Voltage Supply Current Outputs Output Signal (PWM) Output Switched Output Signal (20mA-2.0A direct drive) Resolution Mechanical Rotation Force

Column Mounted Shifter

Prophet Handle

Electronic Joystick

S4 Handle

S7 Handle

Single Axis Lever

9V-32V 100 mA max

9V-32V 105 mA

9V-32V <30 mA at 32V <100 mA at 9V 500 Hz 4 outputs available 5 available 0.3 degree +/- 17 degrees 3 Nm torque

7V-11V <30 mA at 32V <100 mA at 9V Up to 2 available Up to 5 available 0.3 degrees

7V-11V <30 mA at 32V <100 mA at 9V Up to 2 available Up to 2 available 0.3 degrees

9V-32V <30 mA at 32V <100 mA at 9V 1 output 0.3 degrees +/-25 degrees 0.2 N-m

Yes Yes +/- 15 degrees 3 Nm torque

500 Hz 3 available 1 degree

Roller travel +/- 6 mm Roller travel +/- 6 mm 6 mN-m 6 mN-m

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SWITCHES
Switches
The Caterpillar family of switches offers components such as the Rocker Switch to allow the operator to transfer input, such as activation of a locking mechanism, to the electronic control module or component in a cost-effective manner. The Electronic Key Switch operates the on-off switch via a removable key.

Rocker Switches

Electronic Key Switch

Operating Characteristics/ Specifications

Inputs Supply Voltage Leakage Current Outputs Output Signal Protection Mechanical Life Contact Configuration Electrical Life at max. current Max Load Resistive Inductive Lamp

Rocker Switch

Electronic Key Switch

12V-24V min. 250,000 cycles 12 A @ 28V 50,000 cycles 12 A 12 A 5A

9V-16V 6 mA max Switch to +Battery 5 A fuse 0.5 A @ 24V

Environmental Specifications
Standard Specifications Protection Vibration Storage Temperature Operating Temperature Sealing 9.8 G rms 24-2000 Hz three axis 10 G, 10 to 500 Hz

Rocker Switches -50C to +85C -40C to +85C +/-35 kPa Yes

Electronic Key Switch -50C to +85C -40C to +85C Yes

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PEDALS
Pedals
Utilizing our Rotary Position Sensors, the Caterpillar line of pedals is designed for rugged, harsh environments while maintaining a long life cycle of 3 million cycles. Operators appreciate the durability as well as the ease of use.

Compression Pedal

Governor Pedal

Silicone Spring Pedal

Environmental Specifications
Chemical Compatibility Diesel Fuel Water Engine Oil Antifreeze Operating Temperature Range Storage Temperature Range Life Cycle

Silicone Spring Block

Compression Spring

Governor Pedal

Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) -40C to +85C -50C to +85C 3 million cycles

Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) -40C to +85C -50C to +85C 3 million cycles

Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) Yes (SAE J1455 Sec. 4.4) -40C to +85C -50C to +85C 3 million cycles

Operating Characteristics/ Specifications

Inputs Supply Voltage Supply Current Outputs Output Signal at Neutral (% duty cycle) Output Signal at Full Activation (% duty cycle) Electrical Connector Mechanical Pedal Force at Start Pedal Force at Full Travel Treadle Angle Treadle Displacement Treadle Color

Silicone Spring Block

Compression Spring

Governor Pedal

8.0V +/-1% 30 mA max 10% to 22% 75% to 90% Integrated 3-pin DT 44 N 222.4 N 45 +/-2 17 +/-2 Red

8.0V +/-1% 30 mA max 36.5% 58.0% Integrated 3-pin DT 44.5 N 222.4 N 45 +/-2 17 +/-2 Red

8.0V +/-1% 30 mA max 10% to 22% 75% to 90% Integrated 3-pin DT 22 N 44 N 45 +/-2 17 +/-2 Black 33

Electronics Product Directory

SEATING
The Cat Comfort Seat delivers the most support

and durability

you'll find on any equipment. The tough, heavy-duty construction combined with ergonomicdesigned features and extra thick, contoured cushions will provide the operator maximum comfort and reduce fatigue. Cat Comfort Seats and operator restraint systems provide optimum

fit

to 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 costeffective solution for increased

operator comfort, satisfaction and productivity.

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Electronics Product Directory

35

SEATS
Cat Comfort Seat
Operator SatisfactionDesigned to meet comfort, support and restraint needs for operators who share around the clock work schedules. ComfortableErgonomic high-back design and extrathick, contoured cushions provide maximum operator comfort and productivity. SupportiveFit and positioning are similar to that of a personal vehicle or small truck. A three-point shoulder belt keeps the operator comfortably positioned and secured. AdjustableSeat levers and controls are within easy operator reach. Dual Retractor Belt System keeps operators of any size comfortable and secured. DurableProven Toggle Link Suspension has been combined with a durability through simplicity designed seat assembly. This allows for minimal maintenance and a tighter fit of components over the service life of the seat. The seat and suspension have been designed by 10,000-hour life. TestedOver 40,000 hours of testing in rugged high hour off-highway applications, including 5,000 lb. incab 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 Air Suspension An indicator gauge makes it easy for the operator to see the correct amount of air has been added to the system Once adjusted, the seat will maintain the correct setting with no further adjustment until a shift change The Toggle Link Air Suspension system has been proven extremely durable in the most rugged applications, with over 10,000-hour life expectancy
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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 and neck support for maximum operator comfort Dual Retractor Belt System with highly visible two-inch orange shoulder belt which is easily seen when properly worn and latched

Infinitely adjustable lumbar support

Extra-thick, contoured cushions with special side bolsters keep the operator positioned in the center of the seat

Fully adjustable arm rests can be flipped up and out of the way when not in use (dual arm rests are available only on certain applications) Lower cushion tilt adjustment helps reduce operator fatigue and fits a wider range of operator sizes

Cast gears for long life and durability Proven Toggle Link Air Suspension System compensates for the operators weight and provides maximum suspension travel

Dampener adjustment allows the operator to tune the suspension to five firmness settings

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

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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 is

critical. Our robust line of work lights may help improve the work
site visibility for operators and may improve their safety on the job.

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Electronics Product Directory

39

LIGHTS
Today, operators demand well-lit work areas using highly-reliable lights for safety and performance. The Caterpillar Lighting product line satisfies these user requirements by offering the following:

Work Lights
HID Flood Lights 3X3 Halogen

Shock Resistant Lights

Head/Turn Lights

The High Intensity Discharge Gas Lights are used for exterior flood lighting. The color of the light is closer to sunlight than traditional halogen thus providing an increase in operator safety. The HID light is more efficient as it can produce the equivalent of several halogen lights of the same wattage. The gas tube in HID lights has a life expectancy of 2000 to 6000 hours. The 3x3 Halogen Flood Lights are rigid mount lights designed with an advance optical reflector that provides light output nearly approaching that of a 5x5 Flood Light. Shock Resistant lights are designed for general flood lighting. The lens and halogen burner are shock mounted for long-life in high vibration applications and can be mounted either vertically or suspended.

Head/Turn Lights
LED Indicator Lights

With high and low beam driving lights, our stylish head/turn combination light is E marked and approved for all road applications.

LED Lights
Indicator and Signal lights are designed implementing LED technology instead of traditionally used incandescent lighting. The LED technology extends the life of the light and emits brilliant color against EMI/RFI. The LED light also is very cost effective as there is no risk of a filament breaking in high vibration conditions. LED signal lights are now available in amber, red or blue for off-highway and construction equipment. Life expectancy has been extended to approximately 25,000 hours, a greater than 25X improvement over traditional incandescent technology. The light is designed with the lens sonic welded to the housing for 100% sealing.

LED Signal Lights

Strobes
Rotating Beacons use a halogen bulb on a rotating base. Strobes are warning beacons, which use electronics to emit light using a gas tube. As with our other lights, the beacons and strobes are designed to withstand high vibration conditions.

Strobe and Rotating Beacon

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LIGHTS

Environmental Specifications
Operating Temperature Storage Temperature EMI/RFI Environmentally Sealed to:

Rotating Beacon

Strobes

LED Indicator Lights

Combination LED Combination Head/Turn Light Rear Signals

LED Signal Lights

3x3 Halogen Flood Lights

HID Flood Lights

Shock Resistant Lights -40C to +85C -55C to +85C +/-20.6 kPa

-30C to +50C -55C to +85C ISO 13766

-30C to +50C -55C to +85C

-40C to +85C -40C to +85C -40C to +85C -40C to +85C -40C to +85C -40C to +65C -55C to +85C -55C to +85C -55C to +85C -55C to +85C -55C to +85C -55C to +85C Class B Region II Class B Region II Class B Region II Class B Region II 35 kPa 35 kPa +/-35 kPa +/-35 kPa

Operating Specifications
Inputs Supply Voltage Supply Current Chemical Compatibility Diesel Fuel Water Engine Oil Ethylene Glycol

Rotating Beacon

Strobes

LED Indicator Lights

Combination LED Combination Head/Turn Light Rear Signals

LED Signal Lights

3x3 Halogen Flood Lights

HID Flood Lights

Shock Resistant Lights

12V/24V 4.7 A/3.4 A Yes Yes Yes Yes

10V to 32V 1.3 A Yes Yes Yes Yes

12V/24V 30 mA/15 mA Yes Yes Yes Yes

12V/24V 5.4 A/2.7 A Yes Yes Yes Yes

18V to 32V 250 mA Yes Yes Yes Yes

18V to 32V 350 mA Yes Yes Yes Yes

12V/24V 4.7 A/2.4 A Yes Yes Yes Yes

18V to 32V 3.5 A Yes Yes Yes Yes

12V/24V 4.7 A/3.4 A Yes Yes Yes Yes

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ELECTRICAL COMPONENTS
Caterpillar takes great pride in offering electrical components designed to

withstand the harshest environmentsand

theyre 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.

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Electronics Product Directory

43

SENSORS
Caterpillar offers a robust and durable family of sensors for industrial, off-highway, diesel and engine applications. Our product line includes sensor types such as liquid level sensors, pulse width modulated pressure sensors, active speed sensors, high accuracy speed timing sensors, position sensors and temperature sensors. Our sensor offerings include:

Fuel Level Sensor

Liquid Level Sensors

Fuel Level Sensors

Position Sensors
High Pressure PWM Sensor

Cylinder Position Sensors Heavy Duty Rotary Position Sensors Medium Duty Rotary Position Sensors

Pressure Sensors
High Pressure PWM Sensors Integral Connector Pressure Sensors Wire Leaded PWM Pressure Sensors

Medium Duty Rotary Position Sensor

Speed/Timing Sensors
Hall Effect Active Speed Sensors High Accuracy Timing Sensors Low Speed Timing Sensors

Temperature Sensors
Active Temperature Sensor

PWM Exhaust Gas Temperature Sensors PWM Temperature Sensors Active Temperature Sensors Passive Temperature Sensors

Emissions Sensors
Exhaust Gas Thermocouples
Hall Effect Active Speed Sensor

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

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SENSORS
Environmental Specifications
Operating Temperature Storage Temperature Vibration EMI/RFI Sealing Fuel Level Sensor -40C to +125C -60C to +58C 10 G rms (18-2 kHz) 100 V/m Radiated +/-35 kPa High Pressure PWM Pressure Sensor -40C to +110C -55C to +135C 26 G rms (20-2 kHz) 100 V/m +/-35 kPa Integral Connector Pressure Sensor -40C to +125C -55C to +135C 26 G rms (20-2 kHz) 100 V/m +/-35 kPa Wire Leaded PWM Pressure Sensors -40C to +125C -55C to +135C 26 G rms (20-2 kHz) 100 V/m +/-35 kPa Hall Effect Active Speed Sensors -40C to +120C -55C to +150C 20 G rms (20-2 kHz) 100 V/m +/-35 kPa High Accuracy Timing Sensors -40C to +150C -55C to +150C 20 G rms (20-2 kHz) +/-35 kPa

Operating Characteristics/ Specifications

Inputs Supply Voltage Supply Current Proof Pressure Burst Pressure Pressure Range Outputs Output Signal Min Surface Speed Sensing Range Resistance Inductance Resolution (Short-Tall Tank) Response to Step input change (10% to 90% of full scale step) Total Error Band Max Sink Current Max Source Current Short to Ground or Vs Protection

Fuel Level Sensor 18V-32V 80 mA PWM-500 Hz 305-2286 mm 12.7- 25.4 mm Yes

High Pressure PWM Pressure Sensor

Integral Connector Pressure Sensor

Wire Leaded PWM Pressure Sensors

Hall Effect Active Speed Sensors 8V-14V 30 mA max 0-15 kHz 7.25 mA 7.25 mA Yes

High Accuracy Timing Sensors Max 40 kHz Typ 0.38 m/sec Typ 140 Ohms 55 mH @ 1000 Hz

8V-32V 5V +/- .25V 8V +/- .25V 35 mA 20 mA max 20 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 15 ms +/-3% of max pres. (-40C to +125C) 20 mA 20 mA Yes Analog 15 ms +/-3% of max pres. (-40C to +125C) 1.5 mA 1.5 mA Yes PWM-500 Hz 15 ms +/-3% of max pres. (-40C to +125C) 1.5 mA 1.5 mA Yes

Liquid Level Switch

Filter By-Pass Switch

Robust Arm Bar Switch

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SENSORS

Environmental Specifications
Operating Temperature Storage Temperature Vibration EMI/RFI Sealing

Low Speed Timing Sensors

PWM Exhaust Exhaust Gas Temperature Gas Sensors Thermocouples

PWM Temperature Sensors

Temperature Sensors

Active

Passive

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

Operating Characteristics/ Specifications

Inputs Supply Voltage Load Current Response Time from 10% to 90% of a Temperature Change Sensed Temperature Outputs Output Signal Min Surface Speed Frequency Output Range Resistance Inductance

Low Speed Timing Sensors Max 15 kHz Typ 0.25 m/sec Typ 1056 Ohms 420 mH @1000 Hz

PWM Exhaust Exhaust Gas Temperature Gas Sensors Thermocouples 8V +/- .25V 20 mA max <60s -40C to +1095C <25s -40C to +1095C

PWM Temperature Sensors 8V or 24V 3 mA <20s -60C to +120C

Temperature Sensors

Active 5V-8V 3 mA <60s -40C to +120C

Passive 10 mA <15s -50C to +150C

PWM Active Analog Voltage Variable Resistance Type K Thermocouple PWM 500 MHz 500 MHz or 5 kHz 20 to 80% duty cycle 9 to 90% duty cycle 0.2 to 4.5V 1000 Ohms @25C

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SENSORS

Environmental Specifications
Operating Temperature Storage Temperature Vibration EMI/RFI Stop Strength Actuation Force Axial Load Radial Load Hydraulic Pressure Limits: Continuous/Transient Sealing

Cylinder Position Sensor

Rotary Position Sensor

Class 3 -40C to +120C -55C to +150C 15.3 G rms (20 to 2 kHz) 100 V/m 41,358 kPa / 82,717 kPa

Class 2 -40C to +120C -55C to +150C 15.3 G rms (20 to 2 kHz) 100 V/m 41,358 kPa / 82,717 kPa

Heavy Duty -40C to +85C -55C to +85C 20 G rms (24 to 2 kHz) 100 V/m Rad Immunity 60 Nm 1 Nm 1000 N max 1000 N max +/-35 kPa

Medium Duty -40C to +85C -55C to +85C 15.3 G rms (24 to 2 kHz) 100 V/m Rad Immunity +/-25 kPa when mounted per specifications

Operating Characteristics/ Specifications

Inputs Supply Voltage Supply Current Angular Range Outputs Output Signal Frequency Output Low (Sink) Output High (Source) Output (PWM) V (low) maximum<1.0V and V (high) minimum >3.9V Maximum Velocity Hysteresis Resolution Position Accuracy Displacement Range Sensor Life Max Sink Current Linearity Short to Ground or Vs Protection

Cylinder Position Sensor

Rotary Position Sensor

Class 3 10V +1/-3V 100 mA max PWM 500 Hz +/-100 Hz < 1.0V > 3.9V Yes 2000 mm/s < 1.5 X resolution +0.6 mm <4 mm @ 1 MHz, and <1 mm @ 5 MHz +/-0.1% of full stroke or +/- resolution 50 mm to 1200 mm 2 million strokes Yes

Class 2 10V +1/-3V 100 mA max PWM 115 Hz +/-15 Hz < 1.0V > 3.9V Yes 2000 mm/s < .12 X resolution +0.004% or 0.15 mm <0.5 mm @ 1 MHz, and <0.1 mm @ 5 MHz +/-0.05% of full stroke or +/- resolution 50 mm to 2000 mm 2 million strokes Yes

Heavy Duty 18V-32V 40 mA max 140 and 120 deg. PWM 350-700 Hz < 1.0V @ 9 mA sink 2% 3 million cycles 10 mA +/- 2.0% Full scale Yes

Medium Duty 9V-32V or 8V 30 mA max 72, 102, & 310 deg. PWM 350-700 Hz < 5.0V @ 8 mA sink >4.0V @ 1.0 mA source 1% for sensors with spring return 10 million cycles 9 mA +/- 2.5% Full scale Yes

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SENSORS
Operating Characteristics/ Specifications
Inputs Supply Voltage Switching Voltage Leakage Current Contact Rating Voltage Drop Voltage Actuation Outputs Output Signal Protection Mechanical Number of Poles Number of Throws Life Contact Configuration Medium (Hydraulic oil) Medium (Lubricant) Medium (Ethanol) Schematics Pin 1 Pin 2 Max Load Resistive Inductive Lamp Filter By-Pass Switch 12V-24V 0.5 A 100 mV @ 2.5 mA max Switch to Ground Single Single 10,000 cycles N/C side of contact 0.1 A 0.1 A 0.1 A Robust Arm Bar Switch 12V-24V 100V max 0.5 A Switch to Ground Single Double 50,000 cycles Liquid Level Switch 100 mV @ 2.5 mA max 5V-28V Single Single 100,000 cycles 100 mA @ 28V Yes Yes Yes N/C side of contact Common

Environmental Specifications
Standard Specs Protection Vibration Storage Temperature Operating Temperature Mounting Sealing 10 G, 18 to 500 Hz 15.3 G, 24 to 2000 Hz 10 G, 20 to 2000 Hz

Filter By-Pass Switch -40C to +121C 35 kPa Yes

Robust Arm Bar Switch -40C to +85C 10.34 kPa Yes

Liquid Level Switch -40C to +125C Impervious to oil, fuel, salt Yes

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CONNECTORS
Connectors
The Caterpillar Connector Series is a heavy-duty plastic electrical connection system for use with inline, bulkhead and device applications. Applications include wire to wire and wire to PC applications. The sealing plugs can be molded into the plug connectors wire seal cover. Bulkhead connectors are available in multiple sizes along with a wire dress cover providing wire seal protection from pressure wash spray.

Environmental Specifications
Operating Temperature Fluid Compatibility Sealing

Connectors
-40C to +120C Diesel fuel, brake fluid, engine oil, engine coolant 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/ Specifications

Current Rating: Wire Range: Mechanical: Keying: Mating: Connector Sizes Available: 6 key ways plus a universal Jackscrew mating; M6 thread with M4 Allen head 26, 70 & 120 position (plug & receptacle; standard length PC pins) 34 & 48 position (header only; long PC pins) 13 amps per terminal* 14-18 AWG

* Consult Caterpillar for maximum total current carrying capability and application assistance

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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 worlds 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, Caterpillars 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 dusthas 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.