Service Training

MALAGA

777D Off Highway Truck

AUTOMATIC RETARDER CONTROL SYSTEM

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
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

IX. AUTOMATIC RETARDER CONTROL

1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
Adolfo
August 1997
Page:

AUTOMATIC RETARDER CONTROL

IX-1

KEY FEATURES

1. SIMPLIFIED RETARDING ON LONG DOWNHILL HAULS

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

CHAPTER : ARC
777D Off Highway Truck
2. AUTOMATIC AND VISIBLE DIAGNOSTICS

3. PROGRAMMABLE ENGINE CONTROL SPEED

4. COMMUNICATES THROUGH CAT DATA LINK

5. ENGINE OVERSPEED PROTECTION

Page:

AUTOMATIC RETARDER CONTROL SYSTEM

IX-2

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

CHAPTER : ARC
A11 A3
OFF INPUT Diagnostic Display SUPPLY OUTPUT
A26 A4
SUPPLY

777D Off Highway Truck

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
Page:
IX-3

ARC CONTROL VALVE KEEPS 1900 +/- 50 RPM

CONDITIONS:

- ARC ON / OFF SWITCH ON.

CHAPTER : ARC
- ACTUAL GEAR AND SELECTED GEAR THE SAME OR HIGHER

777D Off Highway Truck

- ENGINE SPEED GREATER THAN 1800 RPM.

- THROTTLE RELEASED AND SPEED INCREASING. A10

A17-19
36,37

ARC
B9
B6 B10
B7
A5

- PARKING/SECONDARY BRAKE OFF A21

A16

A11 A3

A26 A4
Page:
IX-4

Engine Overspeed Protection

REQUIRED CONDITIONS:

- Selected transmission gear and actual transmission gear are the same.
- Engine speed greater than the protection activation speed.

CHAPTER : ARC
3400 3500 ACTION

777D Off Highway Truck

PROTECTION ACTIVATION SPEED 2475 RPM 2100 RPM OVERSPEED INDICATOR & ALARM

CONTROL VALVE TRIES TO MAINTAIN

PROTECTION CONTROL SPEED 2560 RPM 2180 RPM 2180 RPM

EPTCII OVERRULES > 2560 RPM > 2180 RPM UPSHIFT ONE GEAR OR DISENGAGE LU

SHUT-OFF SPEED 2450 RPM 2075 RPM CONTROL VALVE STOPS MODULATING

A17-19
A10 36,37

ARC
B9
B6 B10
B7
A5

A21

A16

A11 A3

A26 A4
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AUTOMATIC RETARDER CONTROL BOX

IX-5

Display Mode followed by a a Failure

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

CHAPTER : ARC
Cont. Failure Release the SERVICE switch. 37 Pin
Throttle
connector
Power Eng. Speed 4) Activate the CLEAR switch

777D Off Highway Truck

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

D SERIES TRUCKS DO NOT HAVE SERVICE/ CLEAR SWITCHES

 777D Off Highway Truck
CHAPTER : ARC

MODE 0: Normal mode

1 2 3 4 5 6 7

10

1) Machine Power
2) Control box failure indicator
3) Automatic Retarder
4) Retarder indicator
5) "P" BK indicator
6) Accelerator indicator
7) Engine speed indicator
8) Fault diagnostic indicator
10) Normal mode on/off

MODE 1: Diagnostics

1 2 3 4 5 6 7

10
8

1 2 3 4 5 6 7 1 2 3 4 5 6 7
710: Supply solenoid
8 8
F05: Open circuit
C12: Number of occurences.

Page: IX-6
 777D Off Highway Truck
CHAPTER : ARC

MODE 2: Input Status

1 2 3 4 5 6 7
A21 A16
10 A11

8
A26

A10

A10: ON Engine speed running

A11: ON ARC on/off switch ON GROUNDED
A26: OFF ARC on/off switch OFF OPEN
A16: OFF Auto retarder switch GND (NO PRESSURE)
A21: OFF Retarder switch GROUNDED (PRESSURE)

1) ON Key switch ON
2) OFF ARC box has no defects
3) OFF No air press from auto retard
4) OFF No air press from automatic
or lever retarder valve
5) ON " P" BK ON
6) OFF Throttle pedal released
7) ON engine speed signal
8) OFF no active fault detected
10) ON Not in normal mode

Page: IX-7
 777D Off Highway Truck
CHAPTER : ARC

MODE 3: Output Signals

1 2 3 4 5 6 7
A4: Supply Solenoid
A4 A3 A5 A3: Control Solenoid
10 A5: Retarder Lamp

8 If segment ON, ARC is

sending a voltage to the
solenoid

MODE 4: Harness Code

1 2 3 4 5 6 7
A37 A17 A18
10 A36
A19
8

Segment ON: GROUNDED

A36 A37 A17 A18 A19
777D: GND OPEN GND GND GND

MODE 5: Engine Speed Monitor

1 2 3 4 5 6 7

10
8

070: X 10 = 700 rpm

Page: IX-8
 777D Off Highway Truck
CHAPTER : ARC

MODE 6: Control Speed Program

1
.2 3 4 5 6 7
RETARDING SPEED SETTING
A4 A3 A5 3500
FACTORY PRESET 1900 RPM
10 ADJUSTABLE 1850 TO 1950 RPM
8
3400
FACTORY PRESET 2230 RPM
ADJUSTABLE 2160 TO 2290 RPM

ARC SWITCH MUST BE OFF TO SET WITH ET

MODE 7: Control Valve Counter
1 2 3 4 5 6 7
A37 A17 A18
10 A36
A19
8

57.000.000

BRIEFLY
PRESS SET
SWITCH

1 2 3 4 5 6 7
A37 A17 A18
10 A36
A19
672.000
8
TOTAL 57.672.000 CYCLES

MODULATION RATE: 20Hz or 72000 cycles/ hour

CONTROL VALVE OPERATING HOURS: 801 hours

ERASE FUNCTION AVAILABLE

Page: IX-9
 777D Off Highway Truck
CHAPTER : ARC

MODE 8: SUPPLY VALVE COUNTER

1 2 3 4 5 6 7
A37 A17 A18
10 A36
A19
8

70.000

BRIEFLY
PRESS SET
SWITCH

1 2 3 4 5 6 7
A37 A17 A18
10 A36
A19
8780
8

TOTAL 78780 CYCLES

ERASE FUNCTION AVAILABLE

Page: IX-10
 777D Off Highway Truck
CHAPTER : ARC

MODE 9: Functional Test

1 2 3 4 5 6 7

10
8

REQUIRED CONDITIONS:
- MODE 9 entered
- ARC ON \OFF switch ON
- Throttle pedal released.
- Engine OFF.
- Parking brake engaged.
- Service SET switch activated.

MODE 9 ALL INDICATORS ON EXCEPT 2

SET SWITCH CONTROL & SUPPLY VALVES CYCLE

AIR PRESSURE INCREASES & DECREASES

LEDS & INDICATORS FLASH

Page: IX-11
 777D Off Highway Truck
CHAPTER : ARC

ADDITIONAL FUNCTIONS AVAILABLE THROUGH ET

- ARC INTERNAL CLOCK READING

- HOUR READING OF FIRST AND LAST LOGGED FAULT

- DEFINITION OF EACH LOGGED DIAGNOSTIC CODE

- DISPLAY LOGGED EVENTS

Page: IX-12
 777D Off Highway Truck
CHAPTER : ARC

AUTOMATIC RETARDER CONTROL (ARC)

DIAGNOSTIC GUIDE

1 2 3 4 5 6 7

10
8

The On-board Diagnostic window houses eight status lamps along with a three digit numeric
display. The function of the status lamps is as follows:

1. GREEN lamp which is ON when a nominal 24 Volts is available between pins 1 and 2 of
the control box 37 pin connector.

2. RED lamp which is ON or FLASHING when the CONTROL BOX has FAILED and
should be replaced.

3. AMBER lamp which is ON when the ARC PRESSURE SWITCH is OPEN, which
indicates the presence of brake air pressure at the ARC shuttle valve.

4. AMBER lamp which is ON when the RETARDER is in use as sensed by the CLOSED
retarder pressure switch.

5. AMBER lamp which is ON when the SECONDARY or PARKING BRAKE is in use as

sensed by the OPEN secondary brake pressure switch.

6. AMBER lamp which is ON when the ACCELERATOR PEDAL is depressed as sensed

by an OPEN accelerator pressure switch.

7. GREEN lamp which is on when the ENGINE SPEED sensor is providing a signal to the
control.

8. RED lamp which indicates that the control has detected a FAULT for which a diagnostic
code has been stored in internal memory. The lamp is ON if the fault is still present.

10. AMBER lamp is on if not in normal mode(ON if in service mode)

Page: IX-13
 777D Off Highway Truck
CHAPTER : ARC

LAB EXERCISES
LAB A: INPUT/OUTPUT COMPONENT IDENTIFICATION

Directions: Place the correct letter or number next to the component and give a brief
description of each.

Example:

A Engine Speed Sensor

Signals the engine speed to the ARC. A frequency sensor that generates an AC signal
from the passing flywheel gear teeth.
Input/Output Components:

Harness Code Plug

Automatic Retarder Control

Retarder Pressure Switch

Automatic Retarder Pressure Switch

ARC ON/OFF Switch

Service Switches

Engine Speed Sensor

______ Shuttle valve x2

Page: IX-14
 777D Off Highway Truck
CHAPTER : ARC

LAB EXERCISES

Control Solenoid

Supply Solenoid

Auto Retarder Lamp

CAT Data Link

Page: IX-15
 777D Off Highway Truck
CHAPTER : ARC

LAB EXERCISES
LAB B: POWER UP SEQUENCE AND FAULT CODES - MODES 0 AND 1

Directions: Number the order in which the display sequences are shown.

Example: During display system power up, the display shows:

2 Truck Model Number

1 Lamp Test

3 Unit ID Number

A. During system power up, the ARC display shows:

Display Mode -0-

Lamp Test "888"

Three Digit Part Number

Application Number

ARC ID Number

Diagnostic Codes or "- - -"

Version Number

B. After scrolling to Mode 1, the display shows:

Occurrence Identifier (OID). Describes how many times the fault has occurred.

Component Identifier (CID). Describes the component or signal that may have trouble.

Failure Mode Identifier (FMI). Describes what type of failure has occurred.

C. Write down the three fault code identifiers and describe their meaning.

_________________________________________________________________________

Page: IX-16
 777D Off Highway Truck
CHAPTER : ARC

LAB EXERCISES
Lab C: Interpret Diagnostic Modes 2, 3 and 4

Directions: Using the simulated display supplied and the service manual, identify the Inputs,
Outputs, Harness Code and Application Number.

21 16

11

26

10

ARC INPUTS MODE -2-

4 3 5

ARC OUTPUTS MODE -3-

37 17 18

36 19

APPLICATION NO.

HARNESS CODE MODE -4-

Page: IX-17
 777D Off Highway Truck
CHAPTER : ARC

LAB EXERCISES
Lab E: Control and Supply Solenoid Cycles

Directions: Using the simulated display supplied write the correct cycle count in the blank below
the segments.

CONTROL SOLENOID CYCLES MODE -7-

SUPPLY SOLENOID CYCLES MODE -8-

Page: IX-18
 777D Off Highway Truck
CHAPTER : ARC

LAB EXERCISES
Lab F: Arc control valve operation

Directions:
Test the supply and control solenoid valves to determine if they are operating correctly.

Install 8T0857 (0 to 10000 kPa (0 to 1450 psi)) gauge on the rear slack adjuster pressure tap. During
the functional test in mode 9, the brake pressure must increase and decrease smoothly.

Lab G: Use of the diagnostic service tool (ET):

Using ET and a 777D truck fill in the following table:

1) ARC clock reading _________________

2) Hour readings of first and last logged faults __________________________________

3) Definition and diagnostic code of each logged fault _____________________________________

________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________

4) Definition of each logged event ____________________________________________________

________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________

5) Perform ARC test

6) Print status screen to file

7) Locate active fault, fix and clear fault

Page: IX-19
 777D Off Highway Truck
CHAPTER : ARC

POST TEST
ARC Posttest

Directions: Modified True/False. If a question is false, underline or circle the word or words
that make the statement incorrect and replace with word(s) to make the statement correct.

auto retarder
Example: F 1. This is an engine class.

1. The transmission Actual Gear Switch must be in the same gear position or higher
than the transmission Shift Lever Switch before the ARC will engage the brakes.

2. All stored faults that have been corrected may be cleared using the Service Switches
in Mode 1.

3. If a fault is currently present, the green status lamp to the right of the three digit
display will be illuminated.

4. The Supply and Control Solenoids are located in a compartment behind the cab.

5. Pressing both service switches at the same time will cause the ARC to scroll through
the Diagnostic Display Modes.

Directions: Multiple Choice. Circle the correct letter of the best answer for each question.

6. The ARC control can be used to:

A. Correct a stored fault.

B. Retrieve logged information.
C. Indicate transmission type.
D. None of the above.

7. The ARC has ___ Diagnostic Display Modes:

A. 10
B. 6
C. 8
D. 9

Page: IX-20
 777D Off Highway Truck
CHAPTER : ARC

POST TEST

8. The benefit of the Cat Data Link is:

A. Allows the ARC to share inputs from other electronic controls.

B. Signals the operator when the truck is out of fuel.
C. Signals the operator when he selects the wrong gear.
D. Logs data for use on future truck designs.

9. The general purpose of the ARC is:

A. To send output signals to the transmission hydraulic control.

B. To maintain consistent engine speeds for improved production and brake
cooling.
C. To store diagnostic faults for future display.
D. To correct system faults when they occur.

10. What is the function of the Retarder Pressure Switch?

A. Prevents the machine from moving.

B. Engages the parking brake.
C Does not allow Reverse movement of the machine.
D. Signals the ARC when retarder air is present (manual or automatic).

Directions: Match the component with the correct location by placing the letter next to the
component.

Supply Solenoid Valve A. Compartment in front of the cab

ARC ON/OFF Switch B. Compartment behind the cab
Control Solenoid Valve C. On the ARC mounting bracket
Automatic Retarder Pressure Switch D. Top of flywheel housing
Engine Speed Sensor E. Vertical solenoid on ARC control valve
Service Switches F. In harness near ARC control
Auto Retarder Lamp G. Right front dash panel
Automatic Retarder Control H. ARC front cover
Harness Code Plug I. Horizontal solenoid on ARC control valve
Diagnostic Display Window J. Center front dash panel

Page: IX-21