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Caterpillar Global Mining HMS GmbH, Karl Funke Str. 36, D-44149 Dortmund, Germany GBg BI644795 - BCS3 Return Oil Sensor.docx of 12

25. April. 2014 / 24. Jul. 2014 BI644795-01 (SM 2014-009R1)

A New Programming for the Return Oil Pressure Senso r is Now Used on Certain Hydraulic Mining Shovels.

Hydraulic Mining Shovels: Cat 6030/6030FS Diesel wi th serial-no. 120 276 and up Cat 6040/6040FS Diesel with serial-no. 170 137 an d up Cat 6060/6060FS Diesel with serial-no. 340 177 an d up Cat 6090FS Diesel with serial-no. 400 012, 400 01 4 and up

Attention: Follow appropriate safety procedures and use personal protective equipment as required. Corresponding local safety regulation must always b e observed. Modifying parameters in BCS must be carried out by skilled, trained personnel only. Misuse could lead to serious damage on the excavator. A passcode for BCS3 Service Level 1 and Level 2 is requested. Refer to Service Magazine 2014-005 “BCS Passcodes”.

Description of Change: Programming in the BCS (Board Control System) for the return oil pressure sensor (10 bar) has been optimized. This avoids, in unfavorable circumstances, that BCS reports incorrectly about return filter contaminations.

Service Magazine

BI644795-01 (SM 2014-009R1)

Caterpillar Global Mining HMS GmbH, Karl Funke Str. 36, D-44149 Dortmund, Germany BI644795 - BCS3 Return Oil Sensor.docx of 12

Adaptable To: Machine Group 1 = machines equipped with Servo Controller Type 1 refer to illustration 5a

BI644795-01 (SM 2014-009R1)


Adaptable To: Machine Group 2 = machines equipped with Servo Controller Type 2 refer to illustration 5b

Previous machines can be updated by programming the BCS with optimized parameters. The instruction in illustrations 1 to 10 describes this process. This is necessary only if a 10 bar (illustr. 13) sensor is installed. Attention: A few machines are equipped ex works with a 2,5 bar pressure sensor instead. In this case, BCS frequently reports the below failures:

“1450 Hydraulic Oil Filter 1 Contaminations Code 2B8” “1460 Hydraulic Oil Filter 2 Contaminations Code 2B9” (Cat6090FS /RH400)

although the return filters are not contaminated. The 2,5 sensor could be replaced by the 10 bar sensor. Afterwards the BCS must be adjusted as described in this Service Magazine. Note: Part-Number for 2,5 bar Sensor is 3 703 608 (SAP 1701799) – illustr. 13 Part-Number for 10 bar Sensor is 3 714 746 (SAP 4116578) – illustr. 13

BI644795-01 (SM 2014-009R1)


illustration 1: BCS system

illustration 2: connect a standard USB keyboard

BI644795-01 (SM 2014-009R1)


illustration 3: press “Setup” – enter Code Number – press the green tick – to reach Service Level 1

illustration 4: press “Signal Config”

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illustration 5a: valid for machines, equipped with Servo Controller Type 1 scroll to ID 1450, fill in parameters and tick on “Write” ID = 1450 Exist = tick Analog = tick Typ =Analog Data Unit = Milibar Conversation factor = 4 (only for machines equipped with Servo Controller Type 1) Min = 0 Max = 10000 Error Typ = Hydraulic

Check = tick Permanent Fault Storage = tick Limit = 1500 Logic = tick Condition = “Hydraulic-Oil Temperature >40 ° C Beep Alarm = tick Time delay – Fault active = 10 Time delay – no Fault = 2

Attention: Cat 6090FS (RH400) are equipped with 2 pressure sensors for the return filters. The same parameter must be entered in menu for ID 1460.

BI644795-01 (SM 2014-009R1)


illustration 5b: valid for machines, equipped with Servo Controller Type 2 : scroll to ID 1450, fill in parameters and tick on “Write” ID = 1450 Exist = tick Analog = tick Typ =Analog Data Unit = Milibar Conversation factor = 0,4 (only for machines equipped with Servo Controller Type 2) Min = 0 Max = 10000 Error Typ = Hydraulic

Check = tick Permanent Fault Storage = tick Limit = 1500 Logic = tick Condition = “Hydraulic-Oil Temperature >40 ° C Beep Alarm = tick Time delay – Fault active = 10 Time delay – no Fault = 2

Attention: Cat 6090FS (RH400) are equipped with 2 pressure sensors for the return filters. The same parameter must be entered in menu for ID 1460.

BI644795-01 (SM 2014-009R1)


illustration 6: confirm tor write by tick on “Yes”

illustration 7: 1) enter Code Number for level 2 - 2) confirm on tick - 3) afterwards click on exit

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illustration 8: choose “Contr. Settings”

illustration 9: choose “Servo 3”

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illustration 10: for “Hydraulic-Oil-Filter1 monitoring” Set Value to “7) 0-2500 mbar”

Attention: on Cat 6090FS (RH400) machines, repeat t he setting for “Hydraulic-Oil-Filter 2 monitoring”

click on “Write” and exit

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illustration 11: location of return filter pressure sensor 2B8

illustration 12: return filter sensor 2B8 is located in front of hydraulic tank – exemple photo of Cat6030 Attention: Cat 6090FS is equipped with 2 filter sensors, the second sensor is named 2B9

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illustration 13: photo shows example 2,5 bar sensor. type of 10 bar sensor is PA3026 and PRange = 0 .. 10

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