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B
A
C SIGNAL
GROUND
OSCILLATOR
AMPLIFIER
DUTYCYCLE
ELECTRONICCONTROL
SENSORSUPPLY
THERMISTOR
Service TrainingMALAGA
MACHINE ELECTRONICS
AdolfoDecember 1997
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2P
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E
I R
OHM'S LAW
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3P
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BASICELECTRONIC
SIGNALS• DC SIGNALS
• SINE WAVES
• ANALOG SIGNALS
• PULSE TYPE SIGNALS
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4P
age:
0
12V
Time
6V
Positive Pulse
(D)
+
0
+
Time(C)
Varying Positive
0
12V
Time
6V
7V
Fixed Positive+ 0
12VTime
6V7V
Fixed Negative
-
(A) (B) DCSignals
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5P
age:
0
Time
SINEWAVES
One Hertz
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6P
age:
0Pressure ( kPa)
DC
vo
lts+
ANALOG SIGNALS
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ICS
7P
age:
DIGITAL SIGNALS
TWO DISTINCT
AMPLITUDELEVELS
High
Low
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8P
age:
0
ONE PERIOD
+
OFF
ON
PULSE WIDTH MODULATED"DUTY CYCLE"TIME ON vs TIME OFF
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9P
age:
ELECTRONICCOMPONENTS
Input Devices
Output Devices
Controls
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10P
age:
°C kPaMilesKM RPM Liter SERVCODE X10.. .
MESSAGE CENTERMODULE
GAUGE CLUSTERMODULE
CAT DATA LINK
ACTIONLAMP
ACTIONALARM
DISPLAY DATA LINK
TACHOMETERMODULE
1F
INPUTCOMPONENTS
INPUTCOMPONENTS
ENGINECONTROL
AUTO RETARDERCONTROL
TRANSMISSIONCONTROL
CATERPILLAR MONITORING SYSTEM769D - 777D OFF-HIGHWAY TRUCKS
© 1997 Caterpillar Inc.
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11P
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INPUT COMPONENTS
• SWITCHES
• SENDERS
• SENSORS
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12P
age:
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13P
age:
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14P
age:
SENDER-TYPE
• 0 to 240 OHM
• 70 to 800 OHM
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15P
age:
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16P
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SENSOR-TYPES
• PWM (DIGITAL)• FREQUENCY
• ANALOG• ANALOG to DIGITAL
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17P
age:
1
2
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18P
age:
MAGNETIC FREQUENCYSENSOR
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19P
age:
SMALLSQUARE
WAVE
LARGESQUARE
WAVE
ROTATINGGEAR
SENSING ELEMENT('HALL CELL') HALL CELL
IN SLIP HEAD
OUTPUT
SMALL SIGNALS FROMSENSING ELEMENT
AMP REMOVE DCVOLTAGE
AMPSMALL ACSQUARE
WAVE
TRANSMISSION SPEED
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20P
age:
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ICS
21P
age:
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ICS
22P
age:
DIGITAL TEMPERATURE SENSOR
B + AGND B
Signal C
V +V S+ 8
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23P
age:
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24P
age:
5V
THERMISTER
AMPLIFIER
B
A
C
T
ENGINECONTROL
ANALOGRETURN
SIGNAL (0 - 5V)
ANALOG TEMPERATURE SENSOR
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25P
age:
SIGNALV+
GROUND
ANALOGSECTION DIGITAL CONVERTER
SCHEMATICENVELOPE
PWM OUTPUTTO CONTROL
DISPLAYGRAPHICS
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26P
age:
OUTPUT COMPONENTS
• Main Display Module
• Display Data Link
• Alert Indicators
• Action Lamp/Alarm
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27P
age:
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28P
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.. .
MESSAGE CENTERMODULEGAUGE CLUSTER
MODULE
CAT DATA LINK
ACTIONLAMP
ACTIONALARM
DISPLAY DATA LINK
TACHOMETERMODULE
INPUTCOMPONENTS
INPUTCOMPONENTS
ENGINECONTROL
AUTO RETARDERCONTROL
TRANSMISSIONCONTROL
°C kPa Miles KM RPM LiterSERVCODE X10
CATERPILLAR MONITORING SYSTEM
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29P
age:
0
5
10
15
20
25
30
X100
24 VMPHkm/h
44
AUT
P
R
FOUR GAUGE CLUSTER MODULE
ACTION LAMP
MESSAGE CENTER MODULE
ALERTINDICATORS
SPEEDOMETER /TACHOMETER MODULE
MESSAGEDISPLAY
CATERPILLAR MONITORING SYSTEM
MAIN DISPLAY
MACHINE ELECTRONICS
30Page:
OPERATOR MODES
SERVCODE
41.4
MILES or KM
170
700 RPM
SERVCODE
030
74L
INPUTS
SERVICEMETERMODE
ODOMETERMODE
DIGITALTACHOMETER
MODE
RESETTABLELOAD COUNTER
MODE
DIAGNOSTICSCROLLING
MODE
- ENGINE SPEED / TIMING SENSOR- ALTERNATOR "R" TERMINAL- ENGINE OIL PRESSURE
(During CRANKING the display will show "P" if the engine isequipped with the Caterpillar Engine Pre-Lubrication SystemIf the Ether starting aid is installed an "E" will also appearduring cranking)
- ENGINE SPEED / TIMING SENSOR
- BODY UP SWITCH(AFTER 10 SECOND ACTIVATION)
SERVCODE
271 F05
MID CID, FMI
- TOS
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MODULE IDENTIFICATION CODES
MID
030036027083
ELECTRONIC CONTROL
Caterpillar Monitoring System (CAT MS)Advanced Diesel Engine Management (ADEM)
Electronic Programmable Transmission Control (EPTC II)Automatic Retarder Control (ARC)
CID
096177177248263263271271271324324324601819821821830
DESCRIPTION
Fuel LevelSender or Circuit Open or Shorted to Bat +Torque Converter Temperature Sensor Shorted to Ground (Bat -)
Torque Converter Temperature Signal is incorrectCAT Data Link Communication Abnormal
8 V Sensor Power Supply Shorted to BAt +8 V Sensor Power Supply Shorted to ground (Batt -)
Action Alarm or circuit shorted to Bat +Action Alarm open Circuit
Action Alarm or circuit shorted to ground (Bat -)Action Lamp or Circuit Shorted to Bat +
Action Lamp Open CircuitAction Lamp or Circuit shorted to GroundBrake AIr pressure Sensor signal Incorrect
Display Data Link Error9V Display Supply Shorted to Bat +
9V Display Supply Shorted to Ground (Batt-)Brake Oil Temperature Sensor Signal Incorrect
FMI
F03F04F08F02F03F04F03F05F06F03F05F06F08F02F03F04F08
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age: SERVICE MODES
- 1 -
- 2 -
- 4 -
- 5 -
- 7 -
- 6 -
34
SERVCODE
C
170GA - 1
L 1057
- ON OFF
USMILES
SIKM
- 3 -
C
190GA - 2
kPa
715GA - 3
030
SERVCODE
271 F05SERVCODE
- - -
75
GA - 4
MID CID FMI
USE "S" SERVICE SWITCH TO SCROLL GAUGES
- USE "S" SERVICESWITCH TO SCROLLFAULTS
- USE "C" SERVICESWITCH TO CLEARFAULTS
- ALL GAUGES AND INDICATORSSHOW WORST RECORDED CONDITIONS
- USE "C"SERVICE SWITCHTO CHANGE UNITS
- USE "S" SERVICESWITCH TO TURNOFF
- USE "C" SERVICESWITCH TO TURNON
HARNESS CODE FOR 769D - 777D OHTs
t a t l e
HARNESSCODE
NUMERICREADOUT
SERVICE
LOG
UNITS
PERMAMENTLOADCOUNTECONOMYSHIFT(NOT 777D)
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NEUTRAL OUT TO AUXNEUTRAL OUT TO EMS
START SOLENOID
CONVERTERSPEED
ENGINESPEED
KEY STARTSWITCH
BODY UP
ACTUALGEAR
INDICATOROR
SCRAPERCONTROL
A11A12A13A14A15A16 A34
A33A32A31
A35
B10B9
A17
A18
A19
A36
A37
HARNESSCODE
A10 A21
A22
A23
A24
A25
TRANSMISSIONGEAR SWITCHTOS
TRANSMISSION
A26 A3
A4
A5
EPTC II
A - 37 PIN CONNECTORB - 10 PIN SURE-SEAL CONNECTOR
EPTC IISYSTEM
A9
B4
B3
B1
B6B7
A29
A30
A27
B5
A6
A20
A7
SHIFTLEVERSWITCH
SERVICEBRAKE
SECONDARYBRAKE
BODYRAISE
SERVICE "SET" &"CLEAR" SWITCHES
736 - YL735 - OR734 - WH733 - BR
737 - GN
892 - BR893 - GN
306 - GN
E750 - PU
706 - BR
720 - PU
707 - PU
711 - BR712 - WH713 - OR714 - YL715 - GN716 - BU
307 - OR
D996 - PU
D997 - YL
218-
BK21
7 - BK
219 -
BK
227 -
BK28
0 -
BK
709 -
OR
710 -
GN
721 -
BR72
2 - W
H72
3 - O
R72
4 -
YL
725 -
GN
726 -
BU
703 -
BU70
4 - G
Y70
5 - PK
DATA LINK
UP, DOWN,LOCKUPSOLENOIDS
891 - BU
409 - OR
450 - YL
452- PU
2
10
12
3 4 5
11
6 7 8 9
13
D1 D2 D3
A8708 - YLTRANSMISSIONHOLD (WTS)
BACK-UP ALARMRELAY
B2 321- BR
A5 E767 - GN AUGER SOLENOID
NEUTRAL OUT TO PMC
(DATA LINK)
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34P
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TRANSMISSIONGEAR SWITCHTOS
TRANSMISSION
HARNESSCODE
EPTC II
SHIFTLEVERSWITCH
UP, DOWN,SOLENOIDS
2
10
12
3 4 5
11
6 7 8 9
13
D1 D2 D3
supp
ly
sign
al
GND VERIFY
GN
D V
ER
IFY
SELECT SPEED(UPSHIFT)
CHECK TOS
UPSHIFT
STORE SHIFT
NO SHIFT
TOS SHIFTPOINT ???
EPTC II NORMAL OPERATION
Exceptions:
1) F-N or R-N shifts only if speed below5mph.2) Reverse only if speed below 3mph3) Upshift one gear in case ofoverspeed. L.U. deactivated if in topgear (3500 OHT)
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AUTOMATIC RETARDER CONTROLKEY FEATURES
SIMPLIFIED RETARDING ON LONG DOWNHILL HAULS
- Maximum truck speed at consistant high engine rpm
- High RPM assures adequate XMS & brake cooling
- Reduces torque fluctuations, prolonging brake life.
AUTOMATIC AND VISIBLE DIAGNOSTICS
PROGRAMMABLE ENGINE CONTROL SPEED
COMMUNICATES THROUGH CAT DATA LINK
ENGINE OVERSPEED PROTECTION
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36P
age:
TO BRAKEAIR RELAY
A11
A26
A17-1936,37
A3
A4
A10
A5
A16
A21
B9B10B6
B7
AUTOMATIC RETARDER CONTROL SYSTEM
AUTOMATICRETARDERVALVE
ARC SHUTTLEVALVE
SUPPLYSOLENOID
CONTROLSOLENOID
AUTO RETARDERPRESSURE SWITCH
VENT
SUPPLY OUTPUT
CONTROL OUTPUT
AUTO RETARDERPRESSURE INPUT
RETARDER PRESSURE INPUT
RETARDER LAMP OUTPUT
RETARDERLAMP
DATA LINK
HARNESSCODE PLUG
Diagnostic Display
(ARC)CONTROL
RETARDERAUTOMATIC
HARNESSCODE INPUTS
ENGINE SPEED
SERVICE INPUTS
ARC ON/OFFSWITCH
ON INPUT
OFF INPUT
CLEAR
SET
AIR FROMSERVICE BRAKERESERVOIR
BRAKEPEDALAND VALVE
RETARDERLEVERAND VALVE
RETARDERPRESSURE SWITCH
VENT
ENGINE SPEEDSENSOR
A - 37 PIN CONNECTORB - 10 PIN SURE-SEAL CONNECTOR
SERVICE BRAKESHUTTLE VALVE
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37P
age:
37 Pinconnector
10 PinTo clear logged diagnostics:
1) Access MODE 1 byactivating SERVICE and CLEARswitches until display shows: - 1 -2) Release switches
3) Activate SERVICE switch toaccess diagnostic code to becleared.
Release the SERVICE switch.
4) Activate the CLEAR switchto clear the diagnostic code.5) When all the diagnosticcodes are cleared the displaywill show - - -To return to MODE 0 Activate both switchesuntil display shows - 0 -
AUTOMATIC RETARDER CONTROL
Diagnoticpresent
Power
Cont. Failure
ARC Prssr. Ret. Prssr.Parking Bk.
ThrottleEng. Speed
Display Mode1) 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.
followed by a a FailureMode Identifier such as F27
When all diagnostic Codeshave been displayed thedisplay will show END.
AUTOMATIC RETARDER CONTROL BOX
Service modeindicator
MACHINE ELECTRONICS
38Page:
50%
Torque
50%
Torque RemainsThe Same
Torque
50%
50%
AETA SYSTEM
50% Torqueavailable to wheel
on firm footing 50%
BRAKE SLOWSSPINNING WHEEL
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39P
age:
Operating Principle
Trans. OutputSensor
StandardDifferential
Selector & ProportionalSolenoid Valves
ElectronicControl Box
Wheel Speed Sensors
Spring Applied Parking Brakes
MACHINE ELECTRONICS
40Page:
LAB EXERCISES
SCHEMATICS QUIZ
Directions: Using the truck electrical schematic given complete the following quiz. Fill in the blanksor mark the correct answer.
1 Locate the engine coolant sensor on the schematic. List the schematic grid location and themachine 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 machinesilouette.
___ 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
MACHINE ELECTRONICS
41Page:
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 ______________
