789d_m01_opstat_en_txt

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and may not be used without permission. © 2011 Caterpillar Inc. All Rights Reserved.Caterpillar: Confidential Yellow

Global Manpower DevelopMent

789D Off-HigHwaY TruCk operator’s stationMODule 1 - TexT referenCe

SerV1925

SERV1925 - 12/11 Module 1 - Operator’s Station-2-

Caterpillar: Confidential Yellow

Participants will meet the following learning outcomes during the presentations, lab exercises, and post-assessment of this Operator’s Station module for the 789D Off-Highway Truck course:

Given a visual presentation in the classroom of the 789D Off-Highway •Truck Operator’s Station module, the participant will take notes on the identification,location,andfunctionalityofthemajorcomponentsoftheoperator’s station.

Given a 789D Off-Highway Truck and the Lab 1 Worksheets, the •participant will locate and identify the operator’s station components during a lab exercise.

Given class notes and all reference material, the participant will identify •the correct answers during a post-assessment.

Pre-module learning Outcomes (objectives):

This slide and statement for • the 789D Operator’s Station module should be shown at the beginning of the module.

LEARNING OUTCOMES

Participants will meet the following learning outcomes during the presentations, lab exercises, and post-assessment of this Operator’s Station module for the 789D Off-Highway Truck course:

Given a visual presentation in the classroom of the 789D Off-Highway Truck Operator’s •Stationmodule,theparticipantwilltakenotesontheidentification,location,andfunctionalityofthemajorcomponentsoftheoperator’sstation.

Given a 789D Off-Highway Truck and the Lab 1 Worksheets, the participant will locate •and identify the operator’s station components during a lab exercise.

Given a class notes and all reference material, the participant will identify the correct •answers during a post-assessment.



inTrODuCTiOn

The operator’s station for the 789D is similar to the 789C operator’s station. A standard cab, deluxe cab, or deluxe cold weather cab are available. Operator visibility hasbeenenhancedwith theObjectDetectionSystem.Theoperator can receivebothaudibleandvisual indicationsofdetectedobjects. Inaddition, theoperator’sright hand view is improved due to relocation of the air tank on the chassis.

The following operator’s station components are visible in this image:

Air suspension seat with three-point operator restraint (1) •Secondary Brake Pedal (2)•Multifunction lever (3)•ObjectDetectionSystemmonitor(4)•AdjustableSteeringWheel/Column(TiltandTelescoping)(5)•Quad gage and tachometer (6)•Overhead switch panel (7)•Right dash switch panel (8)•VIMS message center module and keypad (9)•Transmission shift lever (10) •HVAC controls (11) •Trainer seat (12)•

• identify operator’s station main components

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operator’s station CoMponents

The 789D truck hoist system is electronically controlled the same as the 789C. The hoist control lever (arrow) activates the four positions of the hoist control valve. The four positions are: RAISE, HOLD, FLOAT, and LOWER.

AfifthpositionofthehoistvalveiscalledtheSNUBposition.Theoperatordoesnothavecontrolover theSNUBposition. When thebody is lowered, justbefore thebody contacts the frame, the Transmission/Chassis ECM signals the hoist solenoids to move the hoist valve spool to the SNUB position. In the SNUB position, the body floatspeedisreducedtopreventhardcontactofthebodywiththeframe.

The truck should normally be operated with the hoist lever in the FLOAT position. Traveling with the hoist in the FLOAT position will make sure the weight of the body is on the frame and body pads and not on the hoist cylinders. The hoist valve will actually be in the SNUB position.

If the transmission is in REVERSE when the body is being raised, the hoist lever sensor is used to shift the transmission to NEUTRAL. The transmission will remain in NEUTRAL until:

the hoist lever is moved into the HOLD or FLOAT position; and•the shift lever has been cycled into and out of NEUTRAL.•

NOTE: If the truck is started with the body raised and the hoist lever in FLOAT, the lever must be moved into HOLD and then FLOAT before the body will lower.

• identify hoist control lever

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Shown is the center of the front dash panel. Four dash indicators, the four-gauge cluster module, and the speedometer/tachometer module are visible.

The four dash indicators to the left of the four-gauge cluster module are (from top to bottom):

Left turn•Body up: Lights when the body is up; Input is from the body position •sensor.Reverse: Lights when the shift lever switch is in REVERSE.•High beam•

• identify indicators on center of front dash panel

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The four systems monitored by the four-gauge cluster module are (top and bottom, left to right):

Engine coolant temperature: Maximum operating temperature is 107°C •(225°F).Brake oil temperature: Maximum operating temperature is 121°C •(250°F).Systemairpressure:Minimumoperatingpressureis450kPa(65psi).•Fuel level: Minimum operating levels are 15% (Category 1) and 10% •(Category 2).

The three systems monitored by the speedometer/tachometer module are:

Tachometer: Displays the engine speed in rpm.•Ground speed: Displayed in the left side of the three-digit display area •and can be displayed in miles per hour (mph) or kilometers per hour (km/h).Actual gear: Displayed in the right side of the three-digit display area •and consists of two digits that show the actual transmission gear that is engaged. The left digit shows the actual gear (such as “1,” “2,” etc.). The right digit shows the direction selected (“F,” “N,” or “R”).



Located on the right side of the steering column is the manual retarder lever (1). The manual retarder lever is used to modulate engagement of the service brakes on all four wheels. The retarder system allows the machine to maintain a constant speed on long downgrades. The retarder will not apply all of the normal braking capacity.

On the right side of the dash are several rocker switches, the Vital Information Management System (VIMS) message center module (2), the VIMS keypad (3), the heatingandairconditioningtemperatureknob(4),andthefanspeedswitch(5).

The rocker switches (6) on the right side of the dash control the following systems:

Top row (from left to right):

Throttle back-up: Raises the engine speed to 1300 rpm if the throttle •sensor signal is invalid.ARC: Activates the Automatic Retarder Control (ARC) system.•Brake release/hoist pilot: Used to release the parking brakes for •towing and provide hoist pilot oil to lower the body with a dead engine. The small latch must be pushed UP before the switch can be pushed DOWN.TCS test: Tests the Traction Control System (TCS). Use this switch •when turning in a tight circle with the engine at LOW IDLE and the transmission in FIRST GEAR. The brakes should ENGAGE and RELEASE repeatedly. The test must be performed while turning in both directions to complete the test.

• identify controls on right side of dash

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Bottom row (from left to right):

Panel Lights: Use this switch to DIM the panel lights•Idle shutdown timer switch•Air Conditioning: Use this switch to turn ON the air conditioner•Heated mirror switch•

Theidleshutdowntimerswitchallowstheenginetoshutdownafteraspecifictimeperiod after the key start switch is turned off. The amount of idle time is programmed using Cat ET. The following conditions must be met to activate the idle shutdown timer:

The idle shutdown timer switch is ON•The parking brake is ENGAGED•The retarder is OFF•The throttle pedal is RELEASED•The brake pedals are RELEASED•

The five dash indicators (7) to the left of the rocker switches are (from top tobottom):

Right turn•Action lamp: Lights when a Category 2, 2-S, or Category 3 Warning is •active.Stairway Down (if equipped): ON when powered stairway is fully •retracted.Retarder: Lights when the retarder is ENGAGED (Auto or Manual).•Flashes rapidly when a fault in the ARC system is detected.•TCS: Lights when the Traction Control System (TCS) is ENGAGED.•



Locatedonthefloorofthecabare:

Secondary brake pedal (1): Used to modulate application of the parking •brakes on all four wheels.Service brake pedal (2): Used to modulate engagement of the service •brakes on all four wheels. For more precise modulation of the service brakes, use the manual retarder lever on the right side of the steering column.Throttlepedal(3):Athrottlepositionsensor(4)isattachedtothe•throttle pedal. The throttle position sensor provides the throttle position input signals to the Engine ECM.

NOTE: The throttle position must be programmed to the 10 to 90% setting. The earlier trucks must be programmed to a 10 to 50% throttle position. The setting is changed in the Engine ECM configuration screen with Cat ET.

The Engine ECM provides an elevated engine idle speed of 1300 rpm when the enginecoolanttemperatureisbelow60°C(140°F).Therpmisgraduallyreducedto1000rpmbetween60°C(140°F)and71°C(160°F).Whenthetemperatureisabove71°C (160°F), the engine will idle at LOW IDLE (700 rpm).

Increasing the low idle speed helps prevent incomplete combustion and overcooling. To temporarily reduce the elevated idle speed, the operator can release the parking brake or depress the throttle momentarily, and the idle speed will decrease to LOW IDLE for 10 minutes.

Thecabairfilter(5)islocatedtotherightofthethrottlepedal.

• identify components on floor of cab

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To the right of the operator’s seat is the shift console. Located on the shift console are the transmission shift lever (1), the parking brake air valve (2), and the parking brake reset valve (3).

The 789D truck transmission has SIX speeds FORWARD and ONE speed REVERSE. The top gear limit and body up gear limit are programmable through the Transmission/Chassis ECM. The top gear limit can be changed from THIRD to SIXTH. The body up gear limit can be changed from FIRST to THIRD.

• identify components on shift console, right of operator’s seat

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Located in the overhead panel are several switches:

Hazard lights (1)•

Headlights and parking/taillights (2)•

Fog lights (3)•

Accesslights(4)•

Side and rear work lights (5)•

• identify overhead panel switches

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Shown is the fuse, relay, and circuit breaker panel located behind the operator’s seat. The 789D trucks now use fuses and relays in addition to circuit breakers to protect the electrical circuits.

A 12 volt/5 amp power port (1) provides a power supply for 12 volt devices, such as a laptop computer.

A laptop computer with the VIMS software installed can be connected to the diagnostic connector (2) to obtain diagnostic and production information from the VIMS Electronic Control.

A laptop computer with Cat ET software installed can be connected to the Cat Data Link connector (3) to obtain diagnostic information and perform programming functions on all the electronic controls.

• identify fuse and circuit breaker panel

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ViTal infOrMaTiOn ManageMenT SYSTeM (ViMS)

Shown is the Vital Information Management System (VIMS) message center module (1) and the keypad module (2).

The message center module consists of an alert indicator, a universal gauge, and a messagedisplaywindow.ThealertindicatorflasheswhenaCategory1,2,2-S,or3 Warning is present.

The universal gauge displays active or logged data (machine) and maintenance (system) events. The universal gauge will also display the status of a sensor parameter selected for viewing by depressing the GAUGE key on the keypad.

The message display window shows various types of text information to the operator, depending on the menu selected with the keypad. An active event will override most displays until acknowledged by depressing the OK Key.

• identify controls on right side of dash

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The VIMS provides three Warning Categories. The first category requires onlyoperator awareness. The second category states that the operation of the machine and the maintenance procedure of the machine must be changed. The third Warning Category states that the machine must be safely shut down immediately.

warning Category 1

ForaCategory1Warning,thealert indicatorwillflash.Theuniversalgaugemaydisplay the parameter and a message will appear in the message display window. A Category 1 Warning alerts the operator that a machine system requires attention. The “OK” key on the keypad can be used to acknowledge the warning. Some warnings will be silenced for a predetermined period. After this time period, if the abnormal condition is still present, the warning will reappear.

warning Category 2

ForaCategory2Warning, thealert indicatorand theaction lampwillflash. Theuniversal gauge may display the parameter and a message will appear in the message display window. A Category 2 warning alerts the operator that a change in machine operation is required to avoid possible damage to the indicated system. The “OK” key on the keypad can be used to acknowledge the warning. Some warnings will be silenced for a predetermined period. After this time period, if the abnormal condition is still present, the warning will reappear.

warning Category 2-S

ForaCategory2-SWarning,thealertindicatorandtheactionlampwillflashandacontinuous action alarm will sound, which indicates a SEVERE Category 2 Warning. The universal gauge may display the parameter and a message will appear in the message display window. A Category 2-S Warning alerts the operator to immediately change the operation of the machine to avoid possible damage to the indicated system. When the change in operation is made to an acceptable condition, the action alarm will turn off.

warning Category 3

ForaCategory3Warning,thealertindicatorandtheactionlampwillflashandtheaction alarm will sound intermittently. The universal gauge may display the parameter and a message will appear in the message display window. A Category 3 Warning alerts the operator that the machine must be safely shut down immediately to avoiddamagetothemachineorpreventpersonalinjury.SomeCategory3Warningscannot be stopped by pressing the “OK” key.



The previous VIMS main module and the two VIMS interface modules have been replaced by the VIMS ECM (1). The VIMS ECM receives input signals from many switches and sensors (9) located on the machine. The VIMS ECM also communicates with other ECMs on the machine. The VIMS provides the operator and the service technician with a complete look at the current and past conditions of all the systems on the truck.

The TPMS is an integral part of the VIMS. Access to the TPMS information is provided through the VIMS message center module (2) and keypad module (3), or througha laptop computerwith theVIMSpc (4) software installed. TheVIMSmonitors all the systems on the truck, but Cat ET (5) is used for programming, running diagnostic tests, and retrieving logged information from the Engine ECM (6), the Transmission/Chassis ECM (7), and the Brake ECM (8). VIMS communicates with the ECMs and Cat ET over the Cat Data Link (17).

The VIMS ECM communicates with the keypad module over the Keypad Data Link (16), and with the speedometer/tachometer module (13) and gauge cluster module (14)over theDisplayDataLink (15). TheVIMSECMalsosendsoutputsignals to the action lamp (11) and the action alarm (10).

An RS-232 service connector is used to connect a laptop computer with VIMSpc software to upload new source and configuration files, view real time data,or download logged information from the VIMS. The VIMS service key start switch (18) must be in the ON position before the laptop computer with VIMS software will communicate with the VIMS.

• explain operation of ViMS interface modules

ServiceLamp(12)

(18)VIMS Service

Key Start Switch

ActionLamp(11)

ActionAlarm(10)

Sensors (9)

VIMS ECM(1)

VIMS PC (4)

Brake ECM(ARC/TCS) (8)

Cat Data Link (17)

Display DataLink (15)

VITAL INFORMATIONMANAGEMENT SYSTEM

(VIMS)

GaugeClusterModule

(14)

Speedometer/Tachometer

Module(13)

MessageCenterModule

(2)

KeypadModule

(3)

Cat ET (5)Keypad DataLink (16)

EngineECM (6)

Transmission/Chassis ECM (7)

12 3FMPHkm/h

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When the key start switch is turned ON, the VIMS runs through a self test. During theselftest,theblueservicelamp(12)willflashthreetimesifanyloggedeventsarestored in the VIMS ECM and once if no logged events are stored. During normal operation, the service lamp will turn ON to notify the technician that the VIMS has an activedata(machine)ormaintenance(system)event.Theservicelampflashestoindicate when an event is considered abusive to the machine.



The Brake ECM (1), the Transmission/Chassis ECM (2), and the VIMS ECM (3) are located in the rear of the cab.

The Brake ECM controls the Automatic Retarder Control (ARC) system, the Traction Control System (TCS), and rear axle cooling.

The Transmission/Chassis ECM controls the shifting of the transmission, torque converter lockup, thehoistsystem, theneutral-start feature,power trainfilterandtemperature monitoring, and the automatic lubrication feature.

All these electronic controls, along with the Engine ECM, communicate with each other on the Cat Data Link. All the information from these controls can be accessed through the VIMS message center or a laptop computer with Cat ET or VIMSpc software.

Some of the operations that can be performed with a laptop computer with VIMSpc installed are:

View real time data (similar to the status menu of Cat ET)•View payload data•Start and stop a data logger•Calibrate the payload system•Uploadsourceandconfigurationfiles(similartoflashprogramming•other ECMs with Cat ET)

• identify Brake, Transmission/Chassis, and ViMS eCMs

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Assign serial and equipment numbers -Reset onboard date, time, and hourmeter -Download event list, data logger, event recorder, payload data, trend data, -cumulative data, and histogram data

NOTE: For more detailed information on the VIMS, refer to the Service Manual Modules “Off-Highway Truck/Tractors Vital Information Management System (VIMS)--System Operation: (Form RENR2630) and “Off-Highway Truck/Tractors Vital Information Management System (VIMS)--Testing and Adjusting Troubleshooting” (Form RENR2631).



Participants have met the following learning outcomes during the presentations, lab exercises, and post-assessment of this Operator’s Station module for the 789D Off-Highway Truck course:

Given a visual presentation in the classroom of the 789D Off-Highway •Truck Operator’s Station module, the participant took notes on the identification,location,andfunctionalityofthemajorcomponentsoftheoperator’s station.

Given a 789D Off-Highway Truck and the Lab 1 Worksheets, the •participantlocatedandidentifiedtheoperator’sstationcomponentsduring a lab exercise.

Givenclassnotesandallreferencematerials,theparticipantidentified•the correct answers during a post-assessment.

Post-module learning Outcomes (objectives):

This slide and statement for the • 789D Operator’s Station module should be shown at the end of the post-assessment.

LEARNING OUTCOMES

Participants have met the following learning outcomes during the presentations, lab exercises, and post-assessment of this Operator’s Station module for the 789D Off-Highway Truck course:

Given a visual presentation in the classroom of the 789D Off-Highway Truck Operator’s •Stationmodule,theparticipanttooknotesontheidentification,location,andfunctionalityofthemajorcomponentsoftheoperator’sstation.

Given a 789D Off-Highway Truck and the Lab 1 Worksheets, the participant located and •identifiedtheoperator’sstationcomponentsduringalabexercise.

Givenclassnotesandallreferencematerials,theparticipantidentifiedthecorrect•answers during a post-assessment.

789d_m01_opstat_en_txt

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