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Supplement - Dealer/Technician Configuration Program: User Instructions
Supplement - Dealer/Technician Configuration Program: User Instructions
7:
Supplement - Dealer/Technician
Configuration Program: User Instructions
Overview This supplement explains how to use the Dealer/Technician
Configuration Program. The Configuration Program is used to
configure and set specific vehicle parameters. This program runs on a
IBM or IBM compatible personal computer (PC), portable or desktop.
Items Included in the The Configuration Package includes the following items:
Configuration Package
• 3 1/2 in. diskette
• 9-pin connector assembly (P/N 1069051)
• 25-pin connector assembly (P/N 1069052)
• Communication Adapter Module (P/N NA012780) (See Figure
7-1.)
• PC Com. Port Protector (P/N NA014936)
PDMM-0057 7-3
Appendix CATERPILLAR® Reach Service Manual
Software Provided The Configuration Program is provided on a 3 1/2 in. floppy diskette.
This diskette contains the following file:
DCAT2P7.EXE - The executable Configuration Program.
Change Truck Option(s) To add or delete an truck option in the field, the Dealer/Technician
must contact Material Handling Associates for an authorization
number called a Pass-Key. Once the hardware of the option has been
installed, the Configuration Program must be executed and the new
Pass-Key number installed.
NOTE: The new Pass-Key is required in order to run the new option on
the truck.
7-4 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
Start-Up The user starts the Configuration Program by turning the PC power
ON or by entering “DCAT” directly at the DOS prompt of the PC.
If the PC has a black and white (monochrome) monitor, start the
Configuration Program using the following command:
dcat2p7 /b <Enter>
If a color monitor is used, the Configuration Program will
automatically determine the highest resolution available and adjust
the colors accordingly. The command to start the program with a color
monitor is:
dcat2p7 <Enter>
When started, the Configuration Program displays the Caterpillar Logo
and instructs the user to press the <Enter> key.
PDMM-0057 7-5
Appendix CATERPILLAR® Reach Service Manual
Communications Time- The Vehicle Manager expects communications of some sort from the
out Configuration Program. Within 2 minutes, communication link
messages are continually sent to the Vehicle Manager from the PC.
These types of messages are sent automatically as long as the PC is
connected to the Vehicle Manager. This ensures that proper
communications are maintained during the configuration process.
This is necessary due to the Security Status of the truck during
communications.
If the Vehicle Manager does not receive a valid Configuration Program
command within the 2 minutes, the Vehicle Manager will terminate
communications and bring Truck Security back to normal operating
mode.
The communications error message is displayed if communications is
attempted with no response from the truck. Follow the procedure
listed for Start-up Communication Error and retry.
7-6 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
Option List If you want to look at how the vehicle is currently configured, press
the F1 key. The Options screen appears as shown below.
Active options will have a check mark (Ö) to the left. Press any key to
continue.
PDMM-0057 7-7
Appendix CATERPILLAR® Reach Service Manual
Choice Selection Two processes can be executed. One or both selections can be chosen.
Select one or both lines by using the UP/DOWN arrow keys. Press the
Enter key to select the highlighted line. When a function is selected, a
check mark (Ö) will appear to the right of that function. In the figure
below, “Change Truck Option(s)” has been selected.
Once the choices have been made, press the Esc key to start the
configuration process.
7-8 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
MC2
Configuration
Information
Date of Manufacture This parameter holds the actual date that the vehicle was initialized in
Final Assembly at the factory. The date could also be the actual ship
date, depending on customer requirements.
Model Type Vehicles which currently use the Configuration Program are:
• Orderpickers and...
• Reach Trucks
The Model Types are represented as follows:
• Orderpickers are represented as “OPR”
• Reach Trucks are represented as “REA”
Drawbar-Drag/Speed This line will only appear for reach trucks. This is the maximum
calculated speed for a specific truck. This information is included in
the Pass-Key received from Material Handling Associates (MHA).
Serial Number The serial number is represented by the last 5 numbers of the actual
truck serial number. For example: L 12345 is a valid Orderpicker
serial number.
Truck Options This line displays currently installed options for this particular truck.
To view the current active options for the vehicle, press the F1 key.
MC2 Version Number This parameter holds the current MICRO COMMANDNA software
version number.
Deadman Hour Meter The Deadman Hour parameter accumulates time, in whole hours,
whenever the truck is ON and an operator is on the Deadman.
Change Truck To add or delete an option to a truck, the technician must have
Options contacted Material Handling Associates and requested a new Pass-
Key. Material Handling Associates (MHA) is responsible for generating
the new Pass-Key. Every truck produced will require a unique code.
To add or delete an option, a proper Field Installed Option Kit (FIOK)
inquiry must be processed by MHA. The new Pass-Key may be part of
the FIOK inquiry when the paper work is returned to the Dealer; if
not, the Pass-Key must be obtained by phone, fax, or mail.
Additional hardware for the option, if any, must be installed before
this procedure is followed.
To change an option, move the cursor until “Change Truck Option(s)”
is highlighted, then press the Enter key. If another line from the menu
is desired, use the UP/DOWN arrow keys to step through the list.
PDMM-0057 7-9
Appendix CATERPILLAR® Reach Service Manual
When all the desired items have been selected, press the Esc key. The
main menu will disappear and a line for the Pass-Key received from
the MHA appears. The Pass-Key should be entered exactly as received
from the Parts Division. There are exactly 28 characters to be entered.
Valid Truck A check is made to verify that the truck being reconfigured is in fact
the correct truck that is supposed to receive the update. This prevents
7-10 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
changes being made to the wrong truck. Part of the information of the
new Pass-Key is unique, even when a new Pass-Key is entered.
The old Pass-Key must match the current truck Pass-Key that is
stored in the Vehicle Manager. If the Pass-Keys do not match, an error
message is displayed.
Valid Truck Information The Truck Type, Date of Manufacture, and Serial Number are
embedded in the New Pass-Key. These can not be changed and must
be the same as the truck’s current information.
This is a redundant check to ensure this is the correct truck. If any of
these parameters do not match, an error message is displayed.
Valid Entry The final check verifies that the new Pass-Key calculates properly with
the information entered.
If the Pass-Key was entered incorrectly, an error message will be
displayed.
At this point any error is probably due to an entry error. Verify the
Pass-Key received from MHA. If the numbers have been entered
correctly and an error still occurs, contact MHA for help.
When the Configuration Program determines that the information
entered is correct, it begins to send commands to the Vehicle
Manager.
The following figures show the screens which appear when the
complete Pass-Key is entered and the result after pressing Enter.
Figure 7-8: Configuration Menu after Last Character is Entered But Before
Enter Key is Pressed.
PDMM-0057 7-11
Appendix CATERPILLAR® Reach Service Manual
Verification You can verify that the option has been added. Press the F1 key to
display the Option List. A checkmark next to an option indicates that
the option has been successfully added to this vehicle.
Invalid/Incorrect Pass- If the Pass-Key is entered incorrectly or is not the correct one for that
Key vehicle, a message will appear.
7-12 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
Initialize Default Selection of this function sends a command to the Vehicle Manager to
Parameters initialize the Vehicle Function Controller (VFC) to its factory default
values.
These parameters will NOT be reset as a result of initializing the
truck.
NOTE: The hour meters are NOT reset as a result of initializing the
truck.
Orderpicker The factory default parameters for specific models are listed in
Table 7-1 on page 7-14 and Table 7-2 on page 7-14.
PDMM-0057 7-13
Appendix CATERPILLAR® Reach Service Manual
Reach Truck
Parameter Factory Default Value
User Password CAT1
SuperUser Password CAT2
Electronic Key 3
Table 7-2: Factory Default Parameters: Reach Truck
The following figure shows the screen after the Configuration Program
has completed initializing the Vehicle Manager to the factory default
values.
7-14 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
Connector Wiring The diagram below Figure 7-15: shows the proper assembly of both
the 9-pin and 25-pin connectors. Both connectors MUST be female in
order to mate with the COM port on your PC. No other style connector
will work!
PDMM-0057 7-15
Appendix CATERPILLAR® Reach Service Manual
7-16 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
Truck Information:
Model: ________________________________
Serial Number: ________________________________
Date of Manufacture: ________________________________
Options (DCAT List): ________________________________
Problem Description:
Description
_________________________________________________________________________________
_________________________________________________________________________________
__________________________________________________________________________________
Disposition:
Authorization: _____________________ Date: __________
PDMM-0057 7-17
CATERPILLAR® Reach Service Manual Appendix
7:
PDMM-0057 7-19
Appendix CATERPILLAR® Reach Service Manual
7-20 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
PDMM-0057 7-21
Appendix CATERPILLAR® Reach Service Manual
Conversion Table
Conversion
Table To Convert... Multiply by...
Inches to Millimeters 25.4
Inches to Centimeters 2.54
Feet to Meters 0.305
Yards to meters 0.914
Miles to Kilometers 1.609
Fahrenheit to Celsius
(oF - 32)
1.8
Celcius to Fahrenheit
(oC X 1.8) +32
7-22 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
PDMM-0057 7-23
Appendix CATERPILLAR® Reach Service Manual
(Continuation)
4ths 8ths 16ths 32nds 64ths To 3 Places To 2 Places MM Equiv.
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400
7-24 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
PDMM-0057 7-25
A B C D
JPI- JPS8-
1 5
4 CONTROL LATCH
2
2 PC FU5 OPERATOR
3
4
3
2
MEMORY ENABLE
DATA LATCH
DATA IN
DISPLAY 6 9
DISPLAY
350A TP2 SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
H-BRIDGE CONTROL
10 1 5 5
FIELD T1 REVERSE
11 2 4 4
1 WIRING FW-B- FIELD CURRENT
(FW) 12 3 2 2
S1 T3 FIELD CURRENT LIMIT
P FW-2 4 4 H-BRIDGE 1 1
A2 FW-B+ FORWARD
9 5 CONTROL 8 8
2 T2 FIELD PWM
MODULE
7 6 MODULE 7 7
FU6 MD CR1 5 7
FW-2 (HCM) 6 6
PGND
3 450A
TP3 A1 S2 FW-1
T5
3
1
8
9
+12
T4
9
+12V
PGND
FW-1
6 10
FW-B- LOOP
2 11
T1 I-LIMIT
T2 T3 T4
JP
B+
S
JPS12-
5
B1 B2 B1 B2 4 B-
S B+
3
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
JPT1-
4 B+KEY
4 CHOPPER
CONTROL
MODULE
JPT2-
4
JPS1-
4
ARM CURRENT
CHOPPER CONTROL
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LIMIT
TP6 SENSOR 1 1
TP5 CHOPPER ENABLE
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPERATURE
8 8
B CHOPPER PWM
MODULE
e 8 7 7
C1 B-DRIVE PGND
6 6
+12V
5
E 2 PGND
TP4 HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
JPF2- 8 8
14 PC-CONTACTOR
B-PC 7 7
B-CONTACTOR
6 6
5 13
11
B-
B+PC
B-PC
FU1
B-PCF
5
4
5
4
P-CONTACTOR
1S-CONTACTOR
+12V
3 3
B+KEY
2 2
POWER PANEL
FU2 B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
DRIVER
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
X Y
1
P P CNTR
6 B+ B+
B+ F1
FILT FILT 4
F2 F1 PC
2
2
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
7-26 PDMM-0057
E F G H
JPS4- JPC1-
9 9
+12V 14 14
THROTTLE VR1
AGND
11 11
CONTROL HANDLE
2
15 15 S20
LIFT
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3
DIRB SOL
9
DIRB
CONTROL HANDLE
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
3 3 7
SSHIFT RIGHT S9 EQ SOL EQ
10 10
AGND 1 2
SHIELD
B+KEY
3
3
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
DRIVER
ASSEMBLY
(HDA)
4
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11-
11 11
DEADMAN
10 10 S/S 3
2ND EN
9 9
EQ EN 2
8 8
HORN EN
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4
REMOTE 2
MASTSW2
3 3 DIRB 1
2 2
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25 1 2
PRESSURE DIRA 1
24 24 B+KEY
TRAC TEMP 2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
DIRA EN
21
20
21
20 EQ 5
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
1 2 3 4 5 6 4 ORANGE 4
JPP1- REMOTE EPO
6 BLUE 6 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
E F G H
PDMM-0057 7-27
A B C D
JPN2- WL
1 FU9
+ -
B+PCF
HYDRAULIC JP201-1
DRIVER SPL-2
BLACK
ASSEMBLY
2
(HDA) B-PCF
JP201-2
WHITE
5
JP204B-2
WHITE
HYDRAULIC LIGHT
DRIVER JPN3-
ASSEMBLY
1
(HDA) B+KEY JP204A-2
6 JP204B-1 JP204A-1 WHITE
BLACK BLACK FAN
2 FU11
B+PCF
SPL-3 JP203-1 JP206-1 JP206-2
BLACK BLACK WHITE
3
B-PCF
JP203-2
WHITE
7 NOTE:
SPECIAL WIRING REQUIRED WHEN USED WITH KEYED AUX. POWER
A B C D
7-28 PDMM-0057
E F G H
ACCESSORY ACCESSORY
POWER FUSED POWER FUSED
10 AMPS 10 AMPS
2
B-
TS8 B+ B-
TS8 B+
2 1 2 1
SPL-12
SPL-12
FU12
FU12
3
JPN3-1 JPN3-3 TP4 PC-1
NOTE:
KEYED AUX POWER REQUIRES SPECIAL WIRING
WHEN USED WITH WORKING LIGHTS AND OR FAN
NESTED SWITCH 4
TS19- S19
HYDRAULIC TS21-4
DRIVER 4 WHITE COM NC
ASSEMBLY REMOTE EPO
(HDA) 6 TS21-6
BLACK
B-PCF
LIGHT
DA1
+ -
JP202-1 JP202-2
JPS3- 5 4 BLACK WHITE
6 A SPL-1
OUTPUT#1 6
VEHICLE K1
MANAGER 7 *
OUTPUT#2 R5 ALARM
(VM) B 1 2
TZ1
4 7
TS19- +
5 FU10 NO COM
B+PCF -
HYDRAULIC
DRIVER 6
B-PCF
ASSEMBLY
(HDA)
7
*USE JPS3-7 TO K1- FOR FORWARD TRAVEL. USE JPS3-8 TO K1- FOR REVERSE TRAVEL. CONNECT BOTH JPS3-6 & JPS3-7 FOR ALL TRAVEL.
E F G H
PDMM-0057 7-29
A B C D
REMOTE LIFT/LOWER
2
JPN4-
S1
1 2 2
1
B+KEY
2 4 NORMAL
B+F 1 2 POSITION
4
REMOTE 1 1 2
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
3 TS19- TS21-2
GREEN R3 LIFT
2 2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4
RED S18
4 2 1
REMOTE EPO
5
B+KEY
6 TS21-6
B-PCF
4 WHITE
JPN5-1
PPDA
REMOTE EPO K2-4
TP1
K2-7
JPF1-1
5
*REMOVE TP1 ON PPDA
1
DA2
SOL1
2 1 6
S3 VFC
9
6 OUTPUT #3
DA2
NO NC B
3
4 1 K3
7 7
A
COM
A B C D
7-30 PDMM-0057
E F G H
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
TS19- TS21-2 3
GREEN R3 LIFT
2 2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4 S19
S18
4 RED COM NO 2 1
REMOTE EPO
REMOTE EPO
5 EPO
B+KEY
6 TS21-6
B-PCF
WHITE 4
4
JPN5-1 DA2
NO NC B
PPDA
REMOTE EPO
5
TP1
4 1 K2
7
JPF1-1 A
COM
5
*REMOVE TP1 ON PPDA
1
DA2
SOL1
2 1 6
S3 VFC
9
OUTPUT #3
6
DA2
NO NC B
3
4 1 K3
7
A 7
COM
E F G H
PDMM-0057 7-31
A B C D
LEGEND
IDENT. SHEET DESCRIPTION
H 1 HORN
HCM 1 H-BRIDGE CONTROL MODULE
HT 1 HEATSINK TEMPERATURE SENSOR
6 JP202
JP203
2
2
CONNECTOR ON MAST FOR TRAVEL LIGHT
CONNECTOR ON MAST FOR WORKING LIGHT
JP204 2 CONNECTOR ON OHG FOR WORKING LIGHTS
JP205 2 CONNECTOR ON OHG FOR OPERATOR FAN
A B C D
7-32 PDMM-0057
E F G H
Q1 1 CHOPPER TRANSISTOR
WL 2 WARNING LIGHT
7
1. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCH OFF AND
CARRIAGE FULLY LOWERED.
E F G H
PDMM-0057 7-33
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
DISPLAY 6 9
DISPLAY
350A TP2 SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
H-BRIDGE CONTROL
10 1 5 5
FIELD T1 REVERSE
11 2 4 4
1 WIRING FW-B- FIELD CURRENT
(FW) 12 3 2 2
S1 T3 FIELD CURRENT LIMIT
P FW-2 4 4 H-BRIDGE 1 1
A2
3 2
9 5
FW-B+
T2
CONTROL 8 8
FORWARD
FIELD PWM
MODULE
7 6 MODULE 7 7
FU6
1
MD CR1 5 7
FW-2 (HCM) 6 6
PGND
450A +12 +12V
FW-1 3 8 9
TP3 R1 A1 S2 T4 PGND
2 T5 1 9
FW-1
6 10
2 FW-B- LOOP
1S 2 11
T1 I-LIMIT
T2 T3 T4
JP 1
B+
S
JPS12-
5
B1 B2 B1 B2 4 B-
S B+
3
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
CHOPPER CONTROL
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LIMIT
TP6 SENSOR 1 1
TP5 CHOPPER ENABLE
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPERATURE
8 8
B CHOPPER PWM
MODULE
e 8 7 7
C1 B-DRIVE PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
2 2
POWER PANEL
FU2 B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
DRIVER
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
7-34 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
E F G H
PDMM-0057 7-35
A B C D
2 JPN7-
S10 JPN13- S12 *
1 COM NC 1
MASTSW1 INHBTBYP
HYDRAULIC HYDRAULIC
DRIVER 2 2
+12V DRIVER B-PCF
ASSEMBLY ASSEMBLY
3 JPN12-
(HDA) B-PCF (HDA) S13
1 COM NC
LIFT INHBT
*MAST IN FULLY LOWERED POSITION 2
+12V
3
B-PCF
4
STROBE OR WARNING LIGHT
JPN2- WL
1 FU9
+ -
B+PCF
HYDRAULIC JP201-1 JP201-2
DRIVER BLACK WHITE
ASSEMBLY SPL-2
2
(HDA) B-PCF
JP204B-2
WHITE
HYDRAULIC LIGHT
DRIVER JPN3-
ASSEMBLY
1
(HDA) B+KEY JP204B-1 JP204A-1 JP204A-2
6 BLACK BLACK WHITE
FAN
2 FU11
B+PCF
JP203-1 JP206-1 JP206-2
BLACK BLACK WHITE
3 SPL-3
B-PCF
JP203-2
WHITE
7 NOTE:
SPECIAL WIRING REQUIRED WHEN USED WITH KEYED AUX. POWER
A B C D
7-36 PDMM-0057
E F G H
ACCESSORY ACCESSORY
POWER FUSED POWER FUSED
10 AMPS 10 AMPS
2
B-
TS8 B+ B-
TS8 B+
2 1 2 1
SPL-12
SPL-12
FU12
FU12
3
JPN3-1 JPN3-3 TP4 PC-1
NOTE:
KEYED AUX POWER REQUIRES SPECIAL WIRING
WHEN USED WITH WORKING LIGHTS AND OR FAN
NESTED SWITCH
4
TS19-
HYDRAULIC TS21-4 S19
DRIVER 4 WHITE COM NC
ASSEMBLY REMOTE EPO
(HDA)
TS21-6
6 BLACK
B-PCF
LIGHT
DA1
+ -
JP202-1 JP202-2
JPS3- 5 4 BLACK WHITE
6 A SPL-1 6
OUTPUT#1
VEHICLE K1
MANAGER 7 *
OUTPUT#2 R5 ALARM
(VM) B 1 2
TZ1
4 7
TS19- +
5 FU10 NO COM
B+PCF -
HYDRAULIC
DRIVER 6
B-PCF
ASSEMBLY
(HDA) 7
*USE JPS3-7 TO K1- FOR FORWARD TRAVEL. USE JPS3-8 TO K1- FOR REVERSE TRAVEL. CONNECT BOTH JPS3-6 & JPS3-7 FOR ALL TRAVEL.
E F G H
PDMM-0057 7-37
A B C D
REMOTE LIFT/LOWER
2 JPN4-
S1
1 2 2
1
B+KEY
2 4 NORMAL
B+F 1 2 POSITION
4
REMOTE 1 1 2
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
TS19- TS21-2
3 2 GREEN R3 LIFT
2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4
RED S18
4 2 1
REMOTE EPO
5
B+KEY
6 TS21-6
B-PCF
4 WHITE
JPN5-1
PPDA
REMOTE EPO K2-4
TP1
K2-7
JPF1-1
DA2
SOL1
2 1 6
S3 VFC
9
6 OUTPUT #3
DA2
NO NC B
3
4 1 K3
7
7 COM
A
A B C D
7-38 PDMM-0057
E F G H
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
TS19- TS21-2
2 GREEN R3 LIFT 3
2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4 S19
S18
4 RED COM NO 2 1
REMOTE EPO
REMOTE EPO
5 EPO
B+KEY
6 TS21-6
B-PCF
WHITE 4
4
JPN5-1 DA2
NO NC B
PPDA
REMOTE EPO
5
TP1
4 1 K2
7
JPF1-1 A
COM
DA2
SOL1
2 1 6
S3 VFC
9
OUTPUT #3
6
DA2
NO NC B
3
4 1 K3
7
COM
A 7
E F G H
PDMM-0057 7-39
A B C D
LEGEND
IDENT. SHEET DESCRIPTION
2 BL
CCM
2
1
BACKUP LIGHT
CHOPPER CONTROL MODULE
C1 1 CAPACITOR FOR SNUBBER CIRCUIT
CR1 1 DIODE ON FIELD WIRING ASSEMBLY
DA1 2 DIODE ASSY FOR BACKUP ALARM
H 1 HORN
HCM 1 H-BRIDGE CONTROL MODULE
HT 1 HEATSINK TEMPERATURE SENSOR
6 JP202
JP203
2
2
CONNECTOR ON MAST FOR TRAVEL LIGHT
CONNECTOR ON MAST FOR WORKING LIGHT
JP204 2 CONNECTOR ON OHG FOR WORKING LIGHTS
JP206 2 CONNECTOR ON OHG FOR OPERATOR FAN
A B C D
7-40 PDMM-0057
E F G H
Q1 1 CHOPPER TRANSISTOR
WL 2 WARNING LIGHT
7
1. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCH OFF AND
CARRIAGE FULLY LOWERED.
E F G H
PDMM-0057 7-41
+
Low Performance
Remote Lift / Lower
2nd
A Sol. B
Pump Man.
Spool Val.
NOT ON ALL MODELS C
L/H Sol.
Cyl.
R L/L
P
P1 A B P1 CV 1 Cyl.
C Sol 1
D
Remote
Lower
Tank
Lift
P2 P2 CV 2 Rel.
2nd
Sol.
Sol 1
Option
D
Reach
Sol.
Dir A
Sol.
Dir B S/S
A1 Sol.
Sol.
Aux.
P3 Press. EQ
Sol.
A2
Tilt
Steer
Sol.
Ret.
Tank
LEGEND
Pressure Lines
Return Lines
Suction Lines
PDMM-0057 7-42
CATERPILLAR® Reach Service Manual Appendix
Decal Replacement
Decal
2
6
PDMM-0057 7-43
Appendix CATERPILLAR® Reach Service Manual
Decal Replacement
10
3
5
11
9
15
2 13
4 1
7 17
8
8
7-44 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
Decal Replacement
FIGURE 7-10
QTY. DESCRIPTION
ITEM NO.
1 1 Caterpillar Decal (16.25 in. Battery Comp.)
2 1 Lubrication Decal
3 1 Caterpillar Decal (16.25 in. Battery Comp.)
4 1 Cold Storage Decal
5 1 Basic Plate
6 1 Handle Instruction Decal
7 1 Traction Motor Decal
8 1 General Warning Decal
9 AR Auxiliary Plate
10 1 UL Type E Plate
11 2 Battery Warning Decal
12 1 Operator Display Decal
13 1 Caterpillar Decal (21.25 in. Battery Comp.)
14 1 General Warning Decal (14.5 in. Battery Comp., Not Illustrated)
15 1 Caterpillar Decal (14.5 in. Battery Comp.)
PDMM-0057 7-45
Appendix CATERPILLAR® Reach Service Manual
Brush Replacement
Brush If any of the brushes require replacement, the complete brush set
should be replaced. Do not replace just one or two brushes. Refer to
Replacement Figure 7-23 for minimum brush lengths.
24-Volt Trucks
Minimum Commuta- Minimum
Motor Manufacturer Part Number
tor Diameter Length*
2.625 in. 0.75 in.
Drive Advanced 1201792
(66.67 mm) (19.05 mm)
Advanced 2.80 in. 0.62 in.
Lift 1011425
(71.1 mm) (15.8 mm)
2.75 in. 0.62 in.
Auxiliary Advanced 1201793
(69.85 mm) (15.8 mm)
* Measurement of brush length refers to the "short" side dimension.
36-Volt Trucks
Minimum Commuta- Minimum
Motor Manufacturer Part Number
tor Diameter Length*
3.11 in. 0.60 in.
Drive Advanced 1011419
(78.99 mm) (15.24 mm)
Advanced 2.80 in. 0.62 in.
Lift 1011413
(71.1 mm) (15.8 mm)
2.938 in. 0.575 in.
Prestolite 1011412
(75 mm) (14.61 mm)
General Elec- 3.1 in. 0.77 in.
1011426
tric (78.7 mm) (19.6 mm)
2.75 in. 0.62 in.
Auxiliary Advanced 1011418
(69.85 mm) (15.8 mm)
* Measurement of brush length refers to the "short" side dimension.
7-46 PDMM-0057
CATERPILLAR® Reach Service Manual Appendix
Brush Replacement
Brush When ordering replacements, refer to the motor serial number on the
Replacement motor nameplate.
(cont.) Do not substitute brushes. The brushes are matched to the motor
type and application to provide the best service. Substituting brushes
of the wrong grade can cause commutator damage or excessive brush
wear.
Where accessible, new brushes should be seated to the commutator
curvature. This can be accomplished by wrapping a piece of 00
sandpaper around the commutator, seating the brush in the brush
holder, and turning the armature. On smaller motors where space is
limited, a brush seating stone may be used. DO NOT use emery cloth
to seat brushes.
After the brushes are seated, the dust should be blown out of the
motor with dry compressed air [30 psi (206.8 kPa)].
PDMM-0057 7-47