Using The Caterpillar TechStation{1000, 0781, 0785} Caterpillar

Using The Caterpillar TechStation{1000, 0781, 0785} [NEHS0645]
Using The Caterpillar TechStation{1000, 0781, 0785}
1.1. Introduction
2.1. TechStation Registration
3.1. Specifications
4.1. Part Number Arrangements And Descriptions
5.1. Nomenclature
6.1. Operation Section
7.2. Initial Power Up
8.2. After Power Is On
9.2. Using The TechStation
10.2. Uninterruptible Power Source (UPS)
11.2. Power Interruptions
12.2. Resetting The Circuit Breaker
13.2. Power Down
14.2. Charging The Uninterruptible Power Source (UPS)
15.2. Rear Connector Panel
16.2. Telephone/Network Surge Protection
17.1. Monitor Adjustments And Circuit Breaker Reset
18.2. Circuit Breaker Reset
19.1. Optional Accessories
20.1. Fully Integrated SIS Workstation
21.1. Maintenance Section
22.2. Checking And Changing The Fan Filter
23.2. Care And Cleaning Of The TechStation
24.1. Service And Warranty

Typical TechStation


The TechStation is a fan-cooled, rugged, full-function PC workstation for shop floor use. It provides the necessary protection for PC use in a shop environment. Its main purpose is to make service technicians more productive by delivering PC-based diagnostic tools and other PC information to their workplace. The TechStation offers the following features:

* Attractive, long-lasting, water resistant, enclosure with chip-proof color to create a positive shop image.
* Internal IBM Industrial 7585 PC provided with DOS and Windows or OS/2 Warp software.
* Uninterruptible power supply provides power protection against surges, brown outs, and total power loss for up to 10 minutes.
* 43 cm (17 in) SVGA non-interlaced color monitor.
* Two pointing devices. Chose between the Trackpoint (built into the IBM keyboard) or the Cirque GlidePoint. Both devices are provided and are simultaneously functional with TechStations containing a PC.
* Fan, filter, and louver provided for internal cooling.
* Ergonomically-designed for a standing mechanic. A writing area provides workspace for routine job and shop paper work.
* Large caster wheels for easy shop mobility. All components are securely fastened and chosen for shock resistance.
* Optional printer will provide paper copy of test results, when desired.
* Designed for UL approval.

TechStation Registration

Please fill out the registration card supplied with the Techstation and return it to the address listed below. If the registration card is not with the TechStation, copy this registration form and return it.

Computer Age
1811 W. Altorfer Drive
Peoria, IL 61615


Part Number Arrangements And Descriptions

If you are interested in utilizing the TechStation as a Fully Integrated SIS Work Station that is capable of networking to your Dealer Business System (DBS), the Deluxe SIS TechStation is the version recommended for this purpose. Additional hardware and software will be required.

NOTE: AVSpare software such as ET, SIS, ANTARES IWS, and PARTS INTEGRATOR must be purchased separately by the end user. The software is available through the AVSpare Literature System. Refer to the Optional Accessories section in this Tool Operating Manual for additional information.

The following chart provides a quick reference of the available options to the TechStation.

This chart provides detailed information on the exact specifications and configurations of each TechStation.


Illustration 1. Front view. Refer to Chart A for item identification.

Illustration 2. Rear view. Refer to Chart B for item identification.

Illustration 3. CD ROM Drive Bay. Refer to Chart C for item identification.

Illustration 4. Front view interior. Refer to Chart D for item identification.

Illustration 5. View behind the IBM 7585 front access door (4, Illustration 4). Refer to Chart E for item identification.

Illustration 6. Interior rear view. Refer to Chart F for item identification.

Operation Section

Initial Power Up

Before turning the TechStation ON for the first time, perform the following:

1. Fill out and return the TechStation Registration Card.

2. Store the spare key for the front access door in a safe place.

NOTE: Always have a spare key stored away for safe keeping. If a key is lost, have a duplicate made immediately. Spare keys for the rear door latch and top hood latches can be purchased through AVSpare's Parts Distribution System (Part number 128-3243).

3. Open the rear access door and verify the voltage selection switch for the PC is in the correct position.

a. If the voltage range in your location is between 90 and 137 volts, the switch should be set where the "110" or "115" is visible.
b. If the voltage range is between 180 and 265 volts, the switch should be set where the "220" or "230" is visible.

4. Verify that all cable connections to the back of the PC are fastened securely and close the rear access door.

5. Open the front access door and remove any shipping materials used for securing the printer (if purchased), and close the front access door.

6. Plug the TechStation power cord into a properly grounded AC outlet.

7. Turn the power switch ON.

After Power Is On

After the power is ON, verify the following.

1. All fans are operating properly (internal PC fans and rear TechStation fan).
2. The monitor is displaying a stable easy-to-read screen.
3. The PC operating system has successfully booted.
4. The keyboard (including the built-in trackpoint pointing device) is working.
5. The GlidePoint® pointing device is working.
6. The (3.5 in) floppy drive is functioning properly.
7. Any remaining PC peripherals purchased such as a CD ROM Drive, PCMCIA Adapter, modem, or printer are functioning correctly.

If any problems are discovered, refer to the Service and Warranty section of this manual.

Using The TechStation

The TechStation is intended to be used for a variety of PC-based applications. The number of different uses for the TechStation is as broad as it is for any PC. New software for PC use is being developed daily. However, for the purpose of keeping this section of the manual brief, only the most typical Service Technician uses for the TechStation will be addressed.

When connecting the TechStation to a AVSpare engine or machine for maintenance or repair (while using AVSpare's Electronic Technician (ET) software program), use the 7X-1412 American Trucking Association (ATA) Cable or the 7X-1570 AVS Data Link Cable (depending on the engine application). These cables will connect to the Data Link connector located on the rear connector panel of the TechStation. Once connected to an engine or machine, the TechStation can be used like any other PC is used today for performing any of the functions available through the ET software program.

The SIS versions of the TechStation can be used for accessing information within AVSpare's Service Information System (SIS) software program. SIS TechStations come equipped with a caddy 6X speed CD ROM drive for the purpose of being able to access information from the CD's that make up the SIS technical information libraries. The SIS TechStations can be used like any other PC capable of running the SIS software program.

Additionally, the TechStation can be used with AVSpare's 4C-6800 Data Logger Group. There is an area available on the rear access door of the TechStation for mounting the 4C-6815 Data Logger. The 4C-6806 Communication Cable should be used to connect the Data Logger to the Serial RS232 connector located on the rear connector panel of the TechStation for completing the communication connection. With the Data Logger Program (DLP) loaded on the TechStation's internal PC, the TechStation could now be used like any other PC capable of running the DLP software.

Cable hooks are provided on the sides of the TechStation for the convenience of keeping the most commonly used cables readily available. For instance, if the TechStation is connected to engines or vehicles through the 7X-1412 ATA Cable or the 7X-1570 AVS Data Link Cable on a regular basis, these cables could be stored on the provided cable hooks. Additionally, if you use the Data Logger on a regular basis, many of the Data Logger cables could be stored on the cable hooks as well.


For questions, concerns, or routine maintenance on the PC, operating system software, and the other computer peripherals within the TechStation, refer to the manufacturer's operating manuals included with the TechStation. If these instructions are not followed, the TechStation components may be damaged beyond repair.

Uninterruptible Power Source (UPS)

When moving the TechStation from one location to another (within a ten minute walking distance), the power cord for the TechStation can be unplugged without powering down the system. The internal Uninterruptible Power Source (UPS) with its built in battery will take over and keep the TechStation powered (see the Nomenclature section for location of the UPS).

When the unit is under battery power, the UPS will sound a repetitive alarm consisting of four beeps every 30 seconds. It will also illuminate a yellow "On Battery" indicator light.

When the UPS has approximately two minutes of remaining charge, it will begin to beep continuously. It will beep until the unit shuts down or AC power is restored.

NOTE: If the UPS battery is worn or has been previously drained without sufficient time to recharge, the time of operation while in battery backup mode will be less than ten minutes.


If the TechStation is unplugged from AC power for more than ten minutes, and the power switch is in the ON position, the UPS will be drained of its power capacity. At this time the system will shutdown without saving files and properly closing opened programs.

The UPS contained in the TechStation is remotely powered ON and OFF using circuitry controlled by the TechStation's power switch. This circuitry is included in all TechStations containing a PC and UPS.

There is a case that will not allow the UPS to be shut OFF with the TechStation's power switch. If the TechStation is turned ON and then immediately shut OFF within a five second period, the UPS will remain ON. The TechStation's power switch needs to be left in the ON position for at least five seconds, before the UPS can be triggered to turn OFF.

Power Interruptions

The TechStation's internal Uninterruptible Power Source (UPS) is designed to protect the AC power input for the PC and any other peripherals contained within the TechStation against power surges, brown outs, and total black outs.

In the case of black outs, the UPS's internal battery will take over and continue to provide power to the PC and other peripherals for up to ten minutes of uninterrupted operation. However, it is extremely important to shut down the computer, closing all opened programs, before the battery backup is exhausted. Refer to the Uninterruptible Power Source (UPS) section for additional information.

The UPS indicator lights can be seen by opening the rear access door of the TechStation. (See the Interior Rear View photo for location of the UPS).

Resetting The Circuit Breaker

The UPS is equipped with a circuit breaker for over-load protection. If the breaker trips, power to the TechStation will be lost. Before power can be restored, the breaker will have to be reset.

To reset the circuit breaker:

1. Shut the power OFF to the TechStation.

2. Thoroughly examine the TechStation internally for any signs of an electrical failure, usually represented by a visual indication of burning or a burnt odor. If there are signs of damage, refer to the Service and Warranty section in this manual. If there are no signs of damage, proceed to the next step.

3. Reset the circuit breaker, located on the back of the UPS, by pressing the reset button.

4. Turn the power ON. Be ready to immediately shut OFF the power if a problem occurs or the circuit breaker trips again. Refer to the Service and Warranty section in this manual for additional information.

Power Down

When powering down the TechStation, the following sequence should be followed:

1. Save all wanted files, and close all opened programs.

NOTE: If the proper sequence for closing Windows and OS/2 is followed, the system will ask the user if files should be saved before exiting.


There is a potential for losing data and/or locking up the PC, if power to the TechStation is turned OFF prior to exiting the operating system properly.

2. Shut down the operating system (Windows or OS/2) following the OEM instructions.

3. After the "safe to shut down message" appears on the screen, turn the power switch OFF.

4. When possible, the power cord should be left plugged into the AC outlet to allow the internal Uninterruptible Power Supply (UPS) to remain fully charged.

5. If the TechStation is going to be stored for an extended period of time (3 months or longer), the UPS should be recharged periodically.

a. For storage temperatures ranging from - 15 to 30°C (5 to 86°F), the UPS battery should be recharged every 6 months.
b. For storage temperatures ranging from 30 to 45°C (86 to 113°F), the UPS battery should be recharged every 3 months.

NOTE: If the UPS battery is allowed to fully discharge, the TechStation will not power up correctly. If the battery is fully discharged, it must be charged for two to five hours by plugging the TechStation power cord into an AC outlet. The power switch should be OFF during recharging.

Charging The Uninterruptible Power Source (UPS)

Under normal operation, the UPS's battery is continuously charged. Any time the TechStation is plugged into AC power, even with the power switch in the OFF position, the UPS's battery is being charged. However, if the battery is completely discharged, it can be recharged by following the steps listed below:

1. Make sure the power switch is turned OFF.

2. Plug the TechStation into a properly grounded AC outlet.

3. Allow the batteries to charge for two to five hours. After two hours, the UPS battery should have enough charge to power the TechStation.

Rear Connector Panel

Illustration 7. Rear connector panel.
(1) Parallel port. (2) Internal printer port. (3) Serial RS-232 port. (4) Modem port. (5) Network connection ports. (6) Data link port.

1. Parallel Port

The parallel port connector is an extension of the PC's parallel port, and is the same as the parallel port on any PC.

2. Internal Printer Port

The printer connector is internally connected to the printer (if purchased). It should be connected externally to the parallel port connector for proper printer operation (external jumper is provided).

NOTE: When the parallel port is used for connecting other devices, such as newer PC-based diagnostic tools, the external jumper between the internal printer connector and the parallel port connector should be removed. The new device should then be connected directly to the parallel port connector. The internal printer connector should then be connected to a pass-through parallel port (if available) on the new device.

3. Serial RS-232 Port

The serial RS-232 connector is an extension of the PC's serial port, and is the same as the serial port on any PC.

4. Modem port

The modem connector is an extension of the modem port. This port is normally found on the back of PC's containing a modem. It should be used as a standard modem port.

5. Network Connection Ports

The Token Ring, Ethernet AUI, and 10 Base T connector openings are provided for easy installation of their corresponding harness assemblies, available as an optional accessory to the TechStation. If a network card is installed in the TechStation, one of the following four harness assemblies should be purchased.

a. 128-3247 Cable Assembly, Network (Token Ring, TechStation). Female DB9 connector provided for network connection.
b. 128-3251 Cable Assembly, Network (Ethernet AUI, TechStation). Female DB15 connector provided for network connection.
c. 128-3255 Cable Assembly, Network (Token Ring/10 Base T, TechStation). RJ-45 socket provided for network connection.
d. 128-3259 Cable Assembly, Network (5250 Emulation, TechStation). Male DB15 connector provided for network connection.

NOTE: The cable required depends on the network card and the type of network connection common to your location.

6. Data Link Port

The Data Link connector is an extension of the connector on the 7X-1701 Communication Adapter. This connector can be connected to either the 7X-1570 AVS Data Link cable or the 7X-1412 ATA Data Link cable. When connected, the TechStation (while running Cat Electronic Technician (ET) software) can communicate with an Electronic Control Module available on many AVSpare engines.

Telephone/Network Surge Protection

TechStations containing a PC are equipped with an Uninterruptible Power Source (UPS) that has telephone/10 Base T network protection. TechStations come from the factory with the modern connection connected by the cable provided to the UPS input connector. Deluxe TechStations have the internal modem connected to the UPS output connector, thus completing the connection for surge protected modem use.

TechStations that do not have a modem installed, but do have a user installed Ethernet card (with a 10 Base T connection) should be configured by the user so the modem connection to the UPS input connector is replaced with the RJ45 plug on the end of the 128-3255 Network Cable Assembly. A standard RJ45 plug to plug extension cable should then be installed between the UPS output connector and the Ethernet card, thus completing the connection for surge-protected Ethernet use.


The surge protected connectors on the back of the UPS, should NOT be used for protecting an RJ45 Token Ring connection. The UPS connectors are designed to protect a two wire phone connection (modem connection) and a 10 Base T connection (form of Ethernet connection) only. RJ45 Token Ring connections use different pin numbers within the RJ45 connectors then the modem and 10 Base T connections.

If surge protection is necessary for the other optional network connections (described in the Optional Accessories section of this manual), companies such as American Power Conversion, Tripp Lite, and Best Power Technology, Inc. make devices specific for this purpose. Please consult your local computer supply store or refer to the Service and Warranty section of this manual for a contact to consult.

Monitor Adjustments And Circuit Breaker Reset

Illustration 8. Raising the top hood for monitor adjustments or circuit breaker reset.
(1) Monitor adjustments. (2) Prop rod. (3) Prop rod rest. (4) Electrical box. (5) Location of future electrical strip with built-in circuit breaker (behind electrical box).

Occasionally, access to the top interior section of the TechStation, is necessary. For example, if your monitor should go out of adjustment, the monitor adjustments are located at the bottom front of the monitor. This location cannot be reached until the top hood of the TechStation is raised. Additionally, the main circuit breaker for the TechStation is located under the hood. If this breaker is tripped, it must be reset. The top hood of the TechStation can be raised by performing the following steps:

1. Using the special key provided, release the two hood latches (located under the desktop) by turning them counterclockwise. New keys can be purchased by ordering a 128-3243 Key.

2. Raise the hood by using the front handle to lift it upward.

3. As the hood is raised, the prop rod will slide up with the hood from the left side. When the prop rod extends out of the hole, put it into the rest provided.

4. With the hood raised and secured with the prop rod, the monitor can be adjusted as needed. Refer to the manual provided with the TechStation for monitor adjustments.

5. If the circuit breaker has been tripped, it can now be reset by simply pressing the reset button.

Circuit Breaker Reset

Under normal operation, the circuit breaker should never trip. If the circuit breaker does trip, it is probably due to a power surge or an electrical failure within the TechStation. If the circuit breaker trips, follow this procedure:

1. Shut the power OFF to the TechStation.

2. Thoroughly examine the TechStation internally for any signs of an electrical failure (signs of burn damage or a burnt odor). If there are signs of damage, refer to the Service and Warranty section in this manual. If there are no signs of damage, proceed to the next step.

3. Raise the top hood of the TechStation and reset the circuit breaker by pressing the reset button.

4. Turn the power ON, be ready to immediately shut the power OFF in the event of a problem. If a problem is encountered or the circuit breaker trips again, refer to the Service and Warranty section in this manual.

Optional Accessories

Illustration 9. Additional workspace areas for TechStation (available in March 1996).
(1) Additional shelf. (2) Cup Holder/Ash Tray Accessory.

Fully Integrated SIS Workstation

The following software will upgrade the TechStation to directly order parts through your Dealer Business System from within SIS (Fully Integrated SIS Workstation). The following section describes a Fully Integrated SIS Workstation. Call the IWS/DBS Help Desk at (309) 675-4000, and/or contact your SIS Coordinator to find out exactly what is required to have this capability.

NOTE: Communications Manager, PC Support, and either a 5250 Emulation Card or a Network Card, including LAN software, are also required for SIS integration with your Dealer Business System.

A Fully Integrated SIS Workstation is a computer system setup with the ability to tie into your Dealer Business System (DBS), and perform business functions such as parts ordering and warranty reporting. There are specific hardware and software requirements for putting together a workstation with this capability.

The Deluxe SIS TechStation and the Deluxe SIS/Multimedia TechStations, with or without a printer, meet most of the hardware, and some of the software requirements for an integrated workstation.

Deluxe SIS TechStations:

In order for the Deluxe SIS TechStations to fulfill all of the hardware requirements, either a 5250 emulation card or a network card for integrating the TechStation to your DBS will need to be added along with an interface cable between the card and the external connector panel on the TechStation. The type of network will determine the type of network card. The most commonly used network cards are the IBM 16/4 Token Ring or the Ethernet card.

In order to determine which cable assembly will be required for connecting the network card (internal to the PC) to the rear connector panel on the TechStation, refer to the previous section on AVSpare Hardware Accessories for part numbers. If a 5250 emulation card is used instead of a network card, the 128-3259 Adapter Cable will interface it to the rear connector panel on the TechStation.

In order for the Deluxe SIS TechStations to fulfill all of the software requirements, the following software programs will need to be added.

1. ANTARES IWS (available through AVSpare) (optional - only needed for back order capability)
2. Parts Integrator (available through AVSpare)
3. Communications Manager/2 (available through IBM)
4. PC Support/400 (available through IBM and comes with the AS/400 operating system software)
5. Parts List Upload Utility (comes with the Dealer Business System software)
6. LAN Support Software (comes with the LAN system setup at your location) (optional - only needed if a network card is used for tapping into DBS, and not needed with a 5250 emulation card)

With the additions listed above, the Deluxe SIS TechStations could be utilized as Fully Integrated SIS Workstations for ordering parts and reporting warranty.

Maintenance Section

Checking And Changing The Fan Filter

The TechStation's cooling fan should be monitored continuously for proper operation. Additionally, the fan filter should be checked at least once a week for cleanliness. This filter should never be allowed to become so dirty that it gets plugged and does not allow air to flow through it. If the filter is dirty, it should be cleaned or changed immediately.


If the TechStation is operated with a malfunctioning cooling fan or dirty fan filter, the internal PC and its peripherals can sustain permanent damage due to over-heating. Malfunctioning fans and/or dirty filters must be immediately fixed.

The fan filter can be checked and replaced by using the following procedure.

1. With the TechStation turned OFF, remove the fan louver by giving it a firm tug perpendicular to its mounting surface (it simply snaps in and out). Refer to the Rear View photo in the Nomenclature section for location of the fan, filter, and louver.

2. Examine the filter (attached to the back of the louver), remove if necessary. If the filter is dirty, clean it with a vacuum and/or wash with soap and water. If the filter is worn or cannot be cleaned, replace it with a new one.

3. Reinstall the filter and louver.

4. Turn the TechStation ON, and check the fan for proper operation.

Care And Cleaning Of The TechStation

For general cleaning, the TechStation can be wiped off using soap and water with a wet or damp sponge or cloth. AVSpare's 9U-5026 Hand Cleaner will work well for removing grease and grime from the TechStation, and it will also provide a shiny protective coating on the surface. Other general purpose non-abrasive solvent cleaners can be used, as well. If desired, Armour-All could be used in place of AVSpare's 9U-5026 Hand Cleaner to polish and protect the polyethylene shell of the TechStation.


Do not use solvents containing Methyl Ethyl Ketone (MEK) or 1,1,1 Trichloroethane to clean the TechStation. These products will damage the finish of the TechStation.

The monitor bezel can be cleaned with any general purpose glass cleaner. The keyboard can be cleaned by blowing the dirt out of it with an air hose and/or wiping it down with a damp cloth. If the keyboard gets wet, the Unit should be turned OFF and allowed to thoroughly dry before using it again.


The TechStation is moisture resistant, but NOT water proof. The TechStation should never be power washed or rinsed.

If the TechStation is stored for extended periods of time, it should be covered to prevent accumulation of dirt and dust.

Service And Warranty

If you are experiencing a problem with your TechStation, contact the "PC Doctor" at one of the following telephone numbers.

The TechStation is covered by the AVSpare Service Technology Group standard one year warranty offered on all service tools. Additionally, the TechStation comes with a three year warranty on the computer and all peripherals.

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