Service Training

MALAGA

MACHINE ELECTRONICS
ELECTRONIC
CONTROL
SENSOR
SUPPLY

OSCILLATOR

DUTY
CYCLE

A
C

SIGNAL

GROUND

AMPLIFIER
THERMISTOR

Adolfo
December 1997

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OHM'S LAW
E

MACHINE ELECTRONICS

R
I

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BASIC
ELECTRONIC
SIGNALS
SINE WAVES
ANALOG SIGNALS
PULSE TYPE SIGNALS

MACHINE ELECTRONICS

DC SIGNALS

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Fixed Positive

Fixed Negative
0

+ 12V

7V
6V

6V
7V

0
Time
(A)

Varying Positive

Time
(B)

+12V

Positive Pulse

6V

0
Time
(C)

Time
(D)

DC
Signals

MACHINE ELECTRONICS

- 12V

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One Hertz

Time

MACHINE ELECTRONICS

SINE
WAVES

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ANALOG SIGNALS

0
Pressure ( kPa)

MACHINE ELECTRONICS

DC volts

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DIGITAL SIGNALS
High

AMPLITUDE
LEVELS

Low

MACHINE ELECTRONICS

TWO DISTINCT

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PULSE WIDTH MODULATED

"DUTY CYCLE"
TIME ON vs TIME OFF

ON

OFF

ONE PERIOD

MACHINE ELECTRONICS

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ELECTRONIC
COMPONENTS
Input Devices

Controls

MACHINE ELECTRONICS

Output Devices

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CATERPILLAR MONITORING SYSTEM

769D - 777D OFF-HIGHWAY TRUCKS

10

GAUGE CLUSTER
MODULE

MESSAGE CENTER
MODULE

TACHOMETER
MODULE

1F

ACTION
LAMP

C kPa MilesKM RPM Liter SERV

CODE
X10

...

ACTION
ALARM
DISPLAY
DATA LINK

INPUT
COMPONENTS
AUTO RETARDER
CONTROL

TRANSMISSION
CONTROL

ENGINE
CONTROL

1997 Caterpillar Inc.

INPUT
COMPONENTS

MACHINE ELECTRONICS

CAT DATA LINK

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11

INPUT COMPONENTS
SWITCHES
SENSORS

MACHINE ELECTRONICS

SENDERS

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12

MACHINE ELECTRONICS

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13

MACHINE ELECTRONICS

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SENDER-TYPE
70 to 800 OHM

MACHINE ELECTRONICS

0 to 240 OHM

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15

MACHINE ELECTRONICS

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SENSOR-TYPES
FREQUENCY
PWM (DIGITAL)
ANALOG
ANALOG to DIGITAL

MACHINE ELECTRONICS

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MACHINE ELECTRONICS

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MAGNETIC FREQUENCY
SENSOR

MACHINE ELECTRONICS

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TRANSMISSION SPEED
SMALL SIGNALS FROM
SENSING ELEMENT

OUTPUT
ROTATING
GEAR

AMP

AMP
SMALL AC
SQUARE
WAVE

LARGE
SQUARE
WAVE

MACHINE ELECTRONICS

SENSING ELEMENT
('HALL CELL') HALL CELL
IN SLIP HEAD

SMALL
SQUARE
WAVE

REMOVE DC
VOLTAGE

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MACHINE ELECTRONICS

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MACHINE ELECTRONICS

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DIGITAL TEMPERATURE SENSOR

B+
GND
Signal

A
B
C

MACHINE ELECTRONICS

V+
VS
+8

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23

MACHINE ELECTRONICS

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ANALOG TEMPERATURE SENSOR

ENGINE
CONTROL

THERMISTER

A
C
B

5V
SIGNAL (0 - 5V)
ANALOG
RETURN

MACHINE ELECTRONICS

AMPLIFIER

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ANALOG
SECTION

DIGITAL CONVERTER

PWM OUTPUT
TO CONTROL

GROUND

SCHEMATIC
ENVELOPE

DISPLAY
GRAPHICS

MACHINE ELECTRONICS

SIGNAL
V+

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OUTPUT COMPONENTS
Main Display Module
MACHINE ELECTRONICS

Display Data Link

Alert Indicators
Action Lamp/Alarm

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27

MACHINE ELECTRONICS

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CATERPILLAR MONITORING SYSTEM

GAUGE CLUSTER
MODULE

TACHOMETER
MODULE

MESSAGE CENTER
MODULE

kPa

Miles

KM

RPM

...

ACTION
LAMP

Liter
SERV
CODE
X10

ACTION
ALARM

CAT DATA LINK

INPUT
COMPONENTS

AUTO RETARDER
CONTROL

TRANSMISSION
CONTROL

ENGINE
CONTROL

INPUT
COMPONENTS

MACHINE ELECTRONICS

DISPLAY
DATA LINK

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CATERPILLAR MONITORING SYSTEM

MAIN DISPLAY

FOUR GAUGE
CLUSTER MODULE

ALERT
INDICATORS
ACTION LAMP

15

AUT

20

25
X100

R
24 V

MPH
km/h

44

30

SPEEDOMETER /
TACHOMETER MODULE
MESSAGE CENTER
MODULE

MESSAGE
DISPLAY

MACHINE ELECTRONICS

10

MACHINE ELECTRONICS

OPERATOR MODES

INPUTS

SERVICE
METER
MODE

ODOMETER
MODE

DIGITAL
TACHOMETER
MODE

RESETTABLE
LOAD COUNTER
MODE

DIAGNOSTIC
SCROLLING
MODE

SERV
CODE

41.4

30

(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

- TOS

170
RPM

- ENGINE SPEED / TIMING SENSOR

700

74

- BODY UP SWITCH
(AFTER 10 SECOND ACTIVATION)

SERV
CODE

SERV
CODE

030
MID

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- ENGINE SPEED / TIMING SENSOR

- ALTERNATOR "R" TERMINAL
- ENGINE OIL PRESSURE

271 F05
CID, FMI

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MODULE IDENTIFICATION CODES

31

MID

ELECTRONIC CONTROL

030
036
027
083

Caterpillar Monitoring System (CAT MS)

Advanced Diesel Engine Management (ADEM)
Electronic Programmable Transmission Control (EPTC II)
Automatic Retarder Control (ARC)

FMI

DESCRIPTION

096
177
177
248
263
263
271
271
271
324
324
324
601
819
821
821
830

F03
F04
F08
F02
F03
F04
F03
F05
F06
F03
F05
F06
F08
F02
F03
F04
F08

Fuel LevelSender or Circuit Open or Shorted to Bat +

Torque Converter Temperature Sensor Shorted to Ground (Bat -)
Torque Converter Temperature Signal is incorrect
CAT 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 Circuit
Action Lamp or Circuit shorted to Ground
Brake AIr pressure Sensor signal Incorrect
Display Data Link Error
9V Display Supply Shorted to Bat +
9V Display Supply Shorted to Ground (Batt-)
Brake Oil Temperature Sensor Signal Incorrect

MACHINE ELECTRONICS

CID

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SERVICE MODES

32
HARNESS CODE FOR 769D - 777D OHTs

HARNESS
CODE
NUMERIC
READOUT

SERV
CODE

-1-

34

USE "S" SERVICE SWITCH TO SCROLL GAUGES

170

-2-

190
GA - 2

GA - 1

SERVICE

kPa

030
MID

-4-

tatle
MILES

UNITS
PERMAMENT
LOAD
COUNT
ECONOMY
SHIFT
(NOT 777D)

-6-7-

271 F05
CID FMI

- USE "S" SERVICE

SWITCH TO SCROLL
FAULTS
- USE "C" SERVICE
SWITCH TO CLEAR
FAULTS

- ALL GAUGES AND INDICATORS

SHOW WORST RECORDED CONDITIONS

KM

US

-5-

SERV
CODE

SI

- USE "C"SERVICE SWITCH

TO CHANGE UNITS

1057
-

ON

OFF

- USE "S" SERVICE

SWITCH TO TURN
OFF
- USE "C" SERVICE
SWITCH TO TURN
ON

MACHINE ELECTRONICS

LOG

GA - 4

GA - 3
SERV
CODE

---

-3-

75

715

A11
A12
A13
A14
A15
A16

SERVICE
BRAKE

706-BR

A6

SECONDARY
BRAKE

720-PU

A20
D3

ACTUAL
GEAR
INDICATOR
OR
SCRAPER
CONTROL

A31
A32
A33
A34
A35

733-BR
734-WH
735 - OR
736 - YL
737-GN

B9
B10

893-GN
892-BR

DATA LINK

B1

306-GN

STARTSOLENOID

B2

321-BR

BACK-UPALARM
RELAY

B3

409-OR

NEUTRALOUTTOAUX
NEUTRALOUTTOEMS

B4

891-BU

NEUTRALOUTTOPMC

A5

E767-GN

10

A27

A8

KEY START
SWITCH

307-OR

B5

ENGINE
SPEED

450-YL

CONVERTER
SPEED

452-PU

D996-PU
D997-YL

HARNESS
CODE
A-37PINCONNECTOR
B-10PINSURE-SEALCONNECTOR

12

13

(DATA LINK)

A29
A30
B6
A18 A36
A22 A24
B7
A17 A19 A37 A9 A10 A21 A23 A25 A26

TRANSMISSION
TOS
GEARSWITCH
TRANSMISSION

AUGERSOLENOID

A4
A3

A5

UP,DOWN,
LOCKUP
SOLENOIDS

EPTC II
SYSTEM

MACHINE ELECTRONICS

708-YL

11

703-BU
704-GY
705-PK

E750-PU

A7

726-BU

707-PU

TRANSMISSION
HOLD (WTS)

SERVICE"SET"&
"CLEAR"SWITCHES

D2

721-BR
722-WH
723-OR
724 - YL
725-GN

BODY UP

D1

710-GN

BODY
RAISE

EPTC II

217-BK
218-BK
219-BK
280 - BK
227-BK

33

711-BR
712-WH
713-OR
714-YL
715-GN
716-BU

709-OR

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SHIFT
LEVER
SWITCH

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EPTC II NORMAL OPERATION

34
SELECT SPEED
(UPSHIFT)

EPTC II
D1

D2

STORE SHIFT

D3

10

SHIFT
LEVER
SWITCH
GND VERIFY

11

12

13

CHECK TOS

TOS SHIFT
POINT ???
UPSHIFT

NO SHIFT

TRANSMISSION
TOS
GEARSWITCH
TRANSMISSION

GND VERIFY

signal

supply

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
gear (3500 OHT)

UP,DOWN,
SOLENOIDS

MACHINE ELECTRONICS

HARNESS
CODE

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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.

PROGRAMMABLE ENGINE CONTROL SPEED

COMMUNICATES THROUGH CAT DATA LINK
ENGINE OVERSPEED PROTECTION

MACHINE ELECTRONICS

AUTOMATIC AND VISIBLE DIAGNOSTICS

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AUTOMATIC RETARDER CONTROL SYSTEM

36
ENGINE SPEED
SENSOR
ENGINE SPEED

HARNESS
CODE INPUTS

SERVICE INPUTS
B6

SET

B7

CLEAR

HARNESS
CODE PLUG

A17-19
36,37

A10

AUTOMATIC
RETARDER
CONTROL
(ARC)

DATA LINK
B9
B10

RETARDER
LAMP
RETARDER LAMP OUTPUT

A5

RETARDER PRESSURE INPUT

A21

ARC ON/OFF
SWITCH

AUTO RETARDER
PRESSURE INPUT
A16

ON INPUT
A3

A11

Diagnostic Display
A26

AIR FROM
SERVICE BRAKE
RESERVOIR

A4

SUPPLY OUTPUT
SUPPLY
SOLENOID
VENT

VENT

CONTROL
SOLENOID
RETARDER
LEVER
AND VALVE

BRAKE
PEDAL
AND VALVE

ARC SHUTTLE
VALVE

AUTOMATIC
RETARDER
VALVE
AUTO RETARDER
PRESSURE SWITCH

SERVICE BRAKE
SHUTTLE VALVE
RETARDER
PRESSURE SWITCH
A - 37 PIN CONNECTOR
B - 10 PIN SURE-SEAL CONNECTOR

TO BRAKE
AIR RELAY

MACHINE ELECTRONICS

OFF INPUT

CONTROL OUTPUT

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AUTOMATIC RETARDER CONTROL BOX

Display Mode
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.

Cont. Failure
Power

When all diagnostic Codes

have been displayed the
display will show END.

1) Access MODE 1 by
activating SERVICE and CLEAR
switches until display shows:
-12) Release switches

10 Pin

3) Activate SERVICE switch to

access diagnostic code to be
cleared.

Ret. Prssr.
Parking Bk.
Throttle

Release the SERVICE switch.

Eng. Speed

Service mode
indicator
Diagnotic
present
AUTOMATIC RETARDER CONTROL

4) Activate the CLEAR switch

to clear the diagnostic code.
5) When all the diagnostic
codes are cleared the display
will show
--To return to MODE 0
Activate both switches
until display shows
-0-

37 Pin
connector

MACHINE ELECTRONICS

ARC Prssr.

followed by a a Failure
Mode Identifier such as F27 To clear logged diagnostics:

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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38

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Operating Principle
39
Electronic
Control Box

Selector & Proportional

Solenoid Valves

Trans. Output
Sensor

Wheel Speed Sensors

Spring Applied Parking Brakes

MACHINE ELECTRONICS

Standard
Differential

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).

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

_____________

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.

5.

___

grid location

___

machine location (silouette).

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

a)

b)

c)

d)

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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.

9.

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

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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