Service Training

MALAGA

MACHINE ELECTRONICS

ELECTRONIC
CONTROL

OSCILLATOR SENSOR
SUPPLY

DUTY
CYCLE
A

C SIGNAL
AMPLIFIER
B GROUND
THERMISTOR

Adolfo
December 1997
 MACHINE ELECTRONICS
OHM'S LAW

R
E

I
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BASIC
ELECTRONIC
SIGNALS

MACHINE ELECTRONICS
• DC SIGNALS

• SINE WAVES

• ANALOG SIGNALS

• PULSE TYPE SIGNALS

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Fixed Positive Fixed Negative

+ 12V 0

7V
6V 6V
7V

0 - 12V
Time Time
(A) (B)
DC
Signals

MACHINE ELECTRONICS
+ Varying Positive +12V Positive Pulse

6V

0 0
Time Time
(C) (D)
 MACHINE ELECTRONICS
Time
One Hertz

0
WAVES
SINE
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ANALOG SIGNALS
DC volts +

MACHINE ELECTRONICS
0
Pressure ( kPa)
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DIGITAL SIGNALS
High

TWO DISTINCT

MACHINE ELECTRONICS
AMPLITUDE
LEVELS

Low
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PULSE WIDTH MODULATED

"DUTY CYCLE"
TIME ON vs TIME OFF
+ ON

MACHINE ELECTRONICS
0
OFF ONE PERIOD
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ELECTRONIC
COMPONENTS

Input Devices

MACHINE ELECTRONICS
Output Devices

Controls
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CATERPILLAR MONITORING SYSTEM
769D - 777D OFF-HIGHWAY TRUCKS
10

GAUGE CLUSTER TACHOMETER MESSAGE CENTER ACTION

MODULE MODULE MODULE LAMP

1F °C kPa MilesKM RPM Liter SERV

CODE
... X10

ACTION
ALARM

DISPLAY
DATA LINK

MACHINE ELECTRONICS
CAT DATA LINK

INPUT
COMPONENTS
AUTO RETARDER
CONTROL
INPUT
COMPONENTS
ENGINE
TRANSMISSION CONTROL
CONTROL

© 1997 Caterpillar Inc.

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INPUT COMPONENTS
• SWITCHES
• SENDERS

MACHINE ELECTRONICS
• SENSORS
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SENDER-TYPE
• 0 to 240 OHM

MACHINE ELECTRONICS
• 70 to 800 OHM
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SENSOR-TYPES
• FREQUENCY
• PWM (DIGITAL)

MACHINE ELECTRONICS
• ANALOG
• ANALOG to DIGITAL
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2
1
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 MACHINE ELECTRONICS
MAGNETIC FREQUENCY
SENSOR
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TRANSMISSION SPEED

SMALL SIGNALS FROM

SENSING ELEMENT

OUTPUT

ROTATING REMOVE DC
GEAR AMP AMP
VOLTAGE SMALL AC LARGE
SMALL
SQUARE SQUARE SQUARE

MACHINE ELECTRONICS
WAVE WAVE WAVE

SENSING ELEMENT
('HALL CELL') HALL CELL
IN SLIP HEAD
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DIGITAL TEMPERATURE SENSOR

V+ B+ A
VS GND B

MACHINE ELECTRONICS
Signal C
+8
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ANALOG TEMPERATURE SENSOR

THERMISTER ENGINE
CONTROL

MACHINE ELECTRONICS
AMPLIFIER A 5V

C SIGNAL (0 - 5V)
ANALOG
B RETURN
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PWM OUTPUT
ANALOG TO CONTROL
SECTION DIGITAL CONVERTER

MACHINE ELECTRONICS
SIGNAL
V+
GROUND
SCHEMATIC DISPLAY
ENVELOPE GRAPHICS
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OUTPUT COMPONENTS

• Main Display Module

• Display Data Link

MACHINE ELECTRONICS
• Alert Indicators
• Action Lamp/Alarm
 MACHINE ELECTRONICS
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CATERPILLAR MONITORING SYSTEM

28

MESSAGE CENTER ACTION

GAUGE CLUSTER TACHOMETER MODULE LAMP
MODULE MODULE

°C kPa Miles KM RPM Liter

SERV

... CODE
X10

ACTION
ALARM
DISPLAY
DATA LINK

MACHINE ELECTRONICS
CAT DATA LINK

INPUT
COMPONENTS
AUTO RETARDER
CONTROL

INPUT
TRANSMISSION ENGINE COMPONENTS
CONTROL CONTROL
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CATERPILLAR MONITORING SYSTEM

29

MAIN DISPLAY

FOUR GAUGE ALERT

CLUSTER MODULE INDICATORS
ACTION LAMP

P
15 AUT

MACHINE ELECTRONICS
10 20

5
25
X100
R
0 MPH 30 44
24 V
km/h

SPEEDOMETER /
TACHOMETER MODULE
MESSAGE CENTER MESSAGE
MODULE DISPLAY
 MACHINE ELECTRONICS

OPERATOR MODES

INPUTS

- ENGINE SPEED / TIMING SENSOR

- ALTERNATOR "R" TERMINAL
SERVICE SERV - ENGINE OIL PRESSURE
METER CODE
MODE 41.4 (During CRANKING the display will show "P" if the engine is
equipped with the Caterpillar Engine Pre-Lubrication System
If the Ether starting aid is installed an "E" will also appear
during cranking)

MILES or KM
ODOMETER - TOS
MODE 170

DIGITAL RPM
TACHOMETER - ENGINE SPEED / TIMING SENSOR
MODE 700

RESETTABLE - BODY UP SWITCH

LOAD COUNTER (AFTER 10 SECOND ACTIVATION)
MODE L 74

DIAGNOSTIC SERV SERV

SCROLLING CODE CODE
MODE 030 271 F05
MID CID, FMI

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MODULE IDENTIFICATION CODES

31

MID ELECTRONIC CONTROL

030 Caterpillar Monitoring System (CAT MS)
036 Advanced Diesel Engine Management (ADEM)
027 Electronic Programmable Transmission Control (EPTC II)
083 Automatic Retarder Control (ARC)

CID FMI DESCRIPTION

MACHINE ELECTRONICS
096 F03 Fuel LevelSender or Circuit Open or Shorted to Bat +
177 F04 Torque Converter Temperature Sensor Shorted to Ground (Bat -)
177 F08 Torque Converter Temperature Signal is incorrect
248 F02 CAT Data Link Communication Abnormal
263 F03 8 V Sensor Power Supply Shorted to BAt +
263 F04 8 V Sensor Power Supply Shorted to ground (Batt -)
271 F03 Action Alarm or circuit shorted to Bat +
271 F05 Action Alarm open Circuit
271 F06 Action Alarm or circuit shorted to ground (Bat -)
324 F03 Action Lamp or Circuit Shorted to Bat +
324 F05 Action Lamp Open Circuit
324 F06 Action Lamp or Circuit shorted to Ground
601 F08 Brake AIr pressure Sensor signal Incorrect
819 F02 Display Data Link Error
821 F03 9V Display Supply Shorted to Bat +
821 F04 9V Display Supply Shorted to Ground (Batt-)
830 F08 Brake Oil Temperature Sensor Signal Incorrect
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SERVICE MODES
32

HARNESS CODE FOR 769D - 777D OHTs

SERV
HARNESS CODE

CODE -1- 34 USE "S" SERVICE SWITCH TO SCROLL GAUGES

C C kPa
NUMERIC 75
READOUT -2- 170 190 715
GA - 1 GA - 2 GA - 3 GA - 4

SERV SERV - USE "S" SERVICE

CODE CODE
SWITCH TO SCROLL
SERVICE -3- --- 030 271 F05 FAULTS

MID CID FMI - USE "C" SERVICE

SWITCH TO CLEAR

MACHINE ELECTRONICS
FAULTS
- ALL GAUGES AND INDICATORS
LOG -4- tatle SHOW WORST RECORDED CONDITIONS

MILES KM - USE "C"SERVICE SWITCH

UNITS -5- US SI TO CHANGE UNITS

PERMAMENT
LOAD L 1057
COUNT -6-
ECONOMY - USE "S" SERVICE
SWITCH TO TURN
SHIFT -7- - ON OFF OFF
(NOT 777D)
- USE "C" SERVICE
SWITCH TO TURN
ON
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711-BR A11
712-WH A12
SHIFT 713-OR A13 A31 733-BR ACTUAL
LEVER A14 A32 GEAR
33

714-YL 734-WH
SWITCH 715-GN A15 A33 735 - OR INDICATOR
716-BU A16 A34 736 - YL OR
SERVICE A35 737-GN SCRAPER
706-BR A6
BRAKE EPTC II CONTROL
SECONDARY B9 893-GN
720-PU A20 B10 DATA LINK
BRAKE 892-BR
D1 D2 D3
10
BODY 707-PU A7
RAISE 11 2 B1 306-GN STARTSOLENOID
12 13
BODY UP E750-PU A27
B2 321-BR BACK-UPALARM
RELAY
TRANSMISSION 708-YL A8 3 4 5 6 7 8 9
HOLD (WTS)
KEY START (DATA LINK)
307-OR B5
SWITCH NEUTRALOUTTOAUX

MACHINE ELECTRONICS
B3 409-OR NEUTRALOUTTOEMS
ENGINE 450-YL A29
SPEED B4 891-BU NEUTRALOUTTOPMC
CONVERTER 452-PU A30
SPEED
A5 E767-GN AUGERSOLENOID
B6
A18 A36 A22 A24
D996-PU B7 A4
SERVICE"SET"&
"CLEAR"SWITCHES D997-YL A17 A19 A37 A9 A10 A21 A23 A25 A26 A3 A5
280 - BK

724 - YL
722-WH
723-OR
709-OR
710-GN

725-GN
217-BK

726-BU
219-BK

227-BK
218-BK

703-BU
704-GY
705-PK
721-BR

HARNESS
CODE UP,DOWN,
LOCKUP
TRANSMISSION
A-37PINCONNECTOR TOS GEARSWITCH
SOLENOIDS EPTC II
B-10PINSURE-SEALCONNECTOR
TRANSMISSION SYSTEM
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EPTC II NORMAL OPERATION

34

SELECT SPEED
(UPSHIFT)
EPTC II
D1 D2 D3
STORE SHIFT
10

11 2
SHIFT
LEVER 12 13
CHECK TOS
SWITCH

GND VERIFY 3 4 5 6 7 8 9

TOS SHIFT
POINT ???
HARNESS

MACHINE ELECTRONICS
CODE UPSHIFT NO SHIFT

Exceptions:

1) F-N or R-N shifts only if speed below

5mph.
2) Reverse only if speed below 3mph
3) Upshift one gear in case of
overspeed. L.U. deactivated if in top
GND VERIFY

gear (3500 OHT)

supply

signal

TRANSMISSION UP,DOWN,
TOS GEARSWITCH SOLENOIDS
TRANSMISSION
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AUTOMATIC RETARDER CONTROL

KEY FEATURES

SIMPLIFIED RETARDING ON LONG DOWNHILL HAULS

-Maximum truck speed at consistant high engine rpm
- High RPMassuresadequateXMS&brakecooling
-Reducestorquefluctuations,prolongingbrakelife.

MACHINE ELECTRONICS
AUTOMATIC AND VISIBLE DIAGNOSTICS

PROGRAMMABLE ENGINE CONTROL SPEED

COMMUNICATES THROUGH CAT DATA LINK

ENGINE OVERSPEED PROTECTION

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AUTOMATIC RETARDER CONTROL SYSTEM

36

ENGINE SPEED HARNESS

SENSOR CODE INPUTS
ENGINE SPEED A17-19 HARNESS
A10 36,37 CODE PLUG
AUTOMATIC DATA LINK
SERVICE INPUTS B9
B6 RETARDER B10
RETARDER
SET LAMP
B7 CONTROL RETARDER LAMP OUTPUT
CLEAR A5
(ARC)
RETARDER PRESSURE INPUT
A21
ARC ON/OFF
SWITCH AUTO RETARDER
PRESSURE INPUT
A16
ON INPUT CONTROL OUTPUT
A11 A3
OFF INPUT Diagnostic Display SUPPLY OUTPUT

MACHINE ELECTRONICS
A26 A4
SUPPLY
SOLENOID

AIR FROM VENT

SERVICE BRAKE VENT
RESERVOIR
CONTROL
SOLENOID

RETARDER AUTOMATIC
BRAKE LEVER ARC SHUTTLE RETARDER
PEDAL AND VALVE VALVE VALVE
AND VALVE
AUTO RETARDER
SERVICE BRAKE PRESSURE SWITCH
SHUTTLE VALVE
RETARDER
PRESSURE SWITCH
A - 37 PIN CONNECTOR TO BRAKE
B - 10 PIN SURE-SEAL CONNECTOR AIR RELAY
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AUTOMATIC RETARDER CONTROL BOX

Display Mode followed by a a Failure

1) If no diagnostic code have been
logged, display will show
---
2) If diagnostic code have been
logged, display will show a
component number such as
172.
ARC Prssr. Ret. Prssr.
Mode Identifier such as F27 To clear logged diagnostics:
1) Access MODE 1 by 10 Pin
When all diagnostic Codes
have been displayed the activating SERVICE and CLEAR
switches until display shows:
display will show END.
-1-
2) Release switches
3) Activate SERVICE switch to
access diagnostic code to be

MACHINE ELECTRONICS
cleared.
Parking Bk.
Cont. Failure Release the SERVICE switch. 37 Pin
Throttle
connector
Power Eng. Speed 4) Activate the CLEAR switch
to clear the diagnostic code.
Service mode 5) When all the diagnostic
indicator codes are cleared the display
will show
Diagnotic ---
present To return to MODE 0
Activate both switches
until display shows
-0-
AUTOMATIC RETARDER CONTROL
 MACHINE ELECTRONICS

AETA SYSTEM

50%

Torque Remains
The Same

Torque

50%

50%

Torque
50%

50% Torque
available to wheel
on firm footing 50%

BRAKE SLOWS
SPINNING WHEEL

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Operating Principle
39

Electronic
Control Box

Selector & Proportional

Solenoid Valves

Trans. Output
Sensor

MACHINE ELECTRONICS
Standard
Differential
Wheel Speed Sensors

Spring Applied Parking Brakes

 MACHINE ELECTRONICS

LAB EXERCISES

SCHEMATICS QUIZ
Directions: Using the truck electrical schematic given complete the following quiz. Fill in the blanks
or mark the correct answer.

1 Locate the engine coolant sensor on the schematic. List the schematic grid location and the
machine silouette.

___ grid location

___ machine location (silouette).

2 What is the part number of the engine coolant temperature sensor?

_____________

3 What gauge wire s are attached to the sensor in question 2?

a) 14

b) 16

c) 18

d) 20

4. Locate the start aid switch on the schematic. List the shematic grid location and the machine
silouette.

___ grid location

___ machine location (silouette).

5. How many wires are attached to the switch in question 8?

a) 2

b) 3

c) 4

d) 5

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 MACHINE ELECTRONICS

LAB EXERCISES

6. What are the wire numbers & colours attached to the switch in question 5

__________________________________________________

7. Briefly explain what a solid red line represents on the schematic.

___________________________________________________________

8. The ARC displays a CID of 627, the probable malfunction is in the

a) throttle position sensor

b) engine RPM sensor

c) Automatic retarder pressure switch

d) Parking brake pressure switch

9. The electronic control displays a FMI of 4, explain the failure description:

___________________________________________________________

10. At what pressure does the secondary brake pressure switch actuate?

______________________________

11. Locate the right front strut sensor. What colour is the signal wire?

___________________________________________________________

12. What does the letter B mean on the machine silhouette?

___________________________________________________________

13. What is the resistance of the upshift, downshift & LU solenoids ______________

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