Revised May 2003 Newsletter 17

22 January 2001
Version 1.1

Service Training Tech Tips Newsletter

Machine Engine Information

for Instructors Technical Communicators
and Service Reps Worldwide

A Happy New Year and New Millennium to everyone.

This is the first Newsletter to use this new format. The Newsletter is being written and composed
using Quarkxpress, a desktop publishing program which allows many more features than a basic
word processing program. For example we will be able to include photos and artwork such as
diagrams and drawings.

Newsletter and Email Text Adobe Software

In case you have not seen the previous Newsletter, I
have decided not to include the text of the Newsletter in
the email. Most people can now get the attachments or
download from the web, or both. From what I see with
your feedback, unless the recipient is using Lotus Notes,
the text in the email, is so jumbled as to be almost
worthless. PDF files are the safest way to deliver text in
one piece. Also eliminating the email text is a time and
cost saver.
Acrobat Reader can be downloaded free from the web.
Using this program, the PDF files can be viewed and
printed. Taken a step further, a full version of Adobe
Acrobat can be purchased and the file can be
manipulated. This feature is very useful for the
preparation of handouts where the text for example, can
be copied into Microsoft Word and a handout created for
class purposes. Slide presentations can be re-arranged
and edited using the Adobe Acrobat program.

PDF Files For more information on Adobe Acrobat Reader and

Some of our readers may be new to the electronic
delivery of training information. For this reason each
month I will introduce some concepts which will assist
the instructors to build their knowledge of various
techniques. In last month's Newsletter, there was an item
regarding PDF files but without an explanation for the
acronym (acronyms should always be explained once in
the text).
From now on, I will be preparing these Newsletters
using QuarkXpress® as described above. The file is
saved in PDF format. This stands for “Portable
Document Format," and enables the user to download the
document without the necessity of the original software,
in this case QuarkXpress®. Acrobat Reader is needed to
view and print the PDF file.
Adobe Acrobat programs, check the web site below. The
Adobe Reader can be downloaded free from this site:
http://www.adobe.com/
Or here is a quote from their web site:
"Adobe® Portable Document Format (PDF) is the
open de facto standard for electronic document
distribution worldwide. Adobe PDF is a universal file
format that preserves all of the fonts, formatting, colors,
and graphics of any source document, regardless of the
application and platform used to create it. PDF files are
compact and can be shared, viewed, navigated, and
printed exactly as intended by anyone with a free Adobe
Acrobat® Reader™. You can convert any document to
Adobe PDF, even scanned paper, using Adobe Acrobat
4.0 software."
 Training Material Update
Communication
Caterpillar Electronic Technician (Cat ET) Adapter Cables
PC To Machine/Engine Connections This graphic shows
Communication Adapter II the various cables used
Engine Electronic
Control Module (ECM)
207-6845 Universal
Data Link Cable (2 ft) or
196-0055 Serial Cable (25 ft) *
225-5985 Parallel Cable (25 ft) **
with the Communication
STW/E
160-0133 (discontinued) 160-0141 Serial Cable (25 ft) ***
160-0142 Serial Cable, short (10 ft) T Adapters I and II.
To PC Serial USB or
Service Tool
Connector Communication
Parallel Port
This graphic can be
Adapter II
171-4400 (Group)
Supports ATA CDL & CAN data links
237-7547 downloaded for use in
USB/Serial Adapter
* Included with Comm Adapter Group class in PDF format at
** For use only on newer PC's without serial ports
*** For all PC's except IBM Think Pads and Compaq Computers the web site listed on the
Engine Electronic
Communication Adapter I next page. Alternatively,
Control Module (ECM)
139-4166
Data Link Cable (18 ft)
7X1425
Serial Cable (4 ft) STW/E
T
it can be copied from the
last page of the
PC Serial or USB Port
Service Tool
Connector
Newsletter.
Communication
Adapter I
7X1700 (Group)
Supports ATA & CDL data links
To download a current
(discontinued but still in use)
version of this document,
please check page 4 of
the Newsletter for
instructions.

Reprints Pull Up Voltage Pg 6

As I have moved to a new format, I am reprinting I have updated and reprinted Curt Rocke's Pull-Up
some of the information previously published as Voltage treatise. This subject continues to be a source
attachments. This time they are printed in the body of of interest. This document will be available as a
the Newsletter. Some of you have not been able to open separate download and can be used as a class handout.
the attachments in the past. These items are also
available as individual downloads from the web.
ET Course Prerequisites Pg 9
These prerequisites were published with the ET Self
Electronic Technician Study Course and are reprinted with this Newsletter.
As previously announced, there are new ET This list is used as a prerequisite for both machine ET
multimedia self running tutorials available with the and Electronic Engine factory courses. It is
Service Technician Workbench (STW) CD ROM. The recommended that these prerequisites be used for dealer
original ET Self Study Course, printable files and slides, training also.
will continue to be updated and available on the web for
the remainder of this year. See page 4 for down loading As dealer training requirements vary, this list may
instructions. need to be abridged. For this reason, the text may be
modified for dealer use and copied into a Microsoft
Word file for class purposes.
Machine Engine Training Material List Pg 5
There is a list of machine engine training material on
page 5. Some of this material can be downloaded
directly from the Service Training web site.

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 Training Material Update (continued)
3408/12E HEUI Training Material Sampler
This material promised in last month's Newsletter, did
not make it to the web site on time. It is now available at
the URL below.
For a sample of this training material, click on the web
site below and follow the instructions:
Confidentiality
Please use care in sharing the information in these
Newsletters. The Newsletters should be kept within our
company/dealer organisation and should not be shared in
electronic form outside the organization. If necessary,
information can be extracted from the Newsletters with
good judgement and shared with our customers.

https://psmktg.cat.com/srvtrng/catalog/virtual/ The information is designed to help our dealer training

After accessing the address above: staff stay ahead of the technology which of necessity is
proliferating. I include the TC's as they are de-facto
Select "Class Listing." trainers.

Fill out the form and click the "submit" button.

You will see the "3408E/3412E Engine Controls --

Hydraulic Electronic Unit Injection (HEUI)" on the list.

For software related questions about the CD ROM, call

or email to:

Gary A. Robinson Ph: (309) 494-5965

Email: Robinson_Gary_A@CAT.com

https://psmktg.cat.com/srvtrng/contact/staff/robinson

For feedback about the technical content, please send

an email to Nigel Wilkinson:

Email: Wilkinson_Nigel_S@CAT.com

Electronic Delivery
We will have more tips on electronic delivery and
distance learning in the next issues of the Newsletter.

Newsletter Links
The URL's in this Newsletter are linked. This means if
your browser preferences are set correctly, you click on
the link and the browser will display the site listed in the
Newsletter. For example, the URL below is linked to the
Virtual Classroom. Click on the URL to test the process.

https://psmktg.cat.com/srvtrng/catalog/virtual/

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 Home Page Update
Downloads Feedback
The files referenced in this Newsletter listed below are Suggestions for articles and subjects are welcome.
available for downloading at this web site: Feedback for the Newsletter can be directed to the
following address:
https://psmktg.cat.com/srvtrng/contact/staff/nigel/
Nigel Wilkinson
Newsletter NO 17, PDF file Training Consultant
Datalink and ET connecting cables, PDF file Earthmoving Service Training
Bldg. LC 1A-D
Pull-Up Voltage
501 S.W. Jefferson St.
Please check the web site (above) and locate this Peoria IL 61630-2124
Newsletter, No. 17 for downloading instructions.
Phone: (309) 494-5955

Email: Wilkinson_Nigel_S@CAT.com
Web Page Change
One of the results of the survey I conducted last year
was the comment that as information proliferates on the Double click on this URL (or copy to the web browser)
web page, it becomes more difficult to find information for past issues of the Tech Tips Newsletter:
on a particular subject.
https://psmktg.cat.com/srvtrng/contact/staff/nigel/
Jennifer Rawls, our web guru is working on a system
to locate all information on particular subjects. We
should have this update available soon, about the time
you receive this Newsletter. She has also reorganised the
Frequently Asked Questions (FAQ's) to be more user
friendly. Training Material Copies
The following pages contain actual training material to
be used for classes or preparation, as follows:

Web Page Updates 5. List of Available Machine Engine Training

The existing material, (1999 and 2000) Newsletters on Material
the Web page also the FAQ's are now updated and
6. Pull-Up Voltage
suggestions are solicited for improvements, or if errors
are noticed. 9. Electrician Technician (ET) Course Prerequisites

10. ET Connecting Machine/Engine Connections

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 List of Available Machine Engine Training Material

1 Description Slide/Text CD ROM

11. 3500 Electronic Engine Controls - Introduction SEGV 2588

12. 3500 Electronic Engine Controls - Off Highway trucks SEGV 2589

13. 3500 Electronic Engine Controls - 5130 Excavator SEGV 2598

14. 3500 Electronic Engine Controls - D11N Track Type Tractor SEGV 2592

15. 3176B Electronic Engine Controls - Challenger 75C/85C SEGV 2608

16. 3408/12E Engine Controls - 988F/990 Wheel Loaders SEGV 2623

17. 3508 Engine Controls - 992G Wheel Loaders SEGV 2630

18. 3408/12E Engine Controls - Hydraulic Electronic Unit Injection (replaced by #9) SESV 1672

19. 3408/12E Engine Controls - Hydraulic Electronic Unit Injection, Self Study CD SERV 7007

10. 3500B Engine Controls - Electronic Unit Injection (EUI) SESV 1681

11. 3406E Engine Controls - D400E Articulated Dump Trucks SESV 1712 SERV 1712

12. 3456 Engine Controls - 988G Wheel Loader SEGV 2675 SERV 2675

13. 3176/3196 Electronic Engine Controls - Challenger 65E/75E/85E/95E SEGV 2636

14. STW Course SEGQ 4084

15. C-9 Engine Controls SERH 4050

SERV prefix indicates available in CD ROM form

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 Pull-Up Voltage

Application:

All Machines with Sensor and Switch Inputs to

Electronic Control Modules (ECM's)

References:

• Service Manual article for system under test

• Service Magazine SEPD0318 "What Is Pull-Up Voltage?" (2 Aug 96)

• To download a current version of this document, please check page 4 of this Newsletter for instructions.

The following is an explanation of "Pull-Up Voltage" found on switch and sensor inputs of electronic controls and
ECM's.

Question: What is "Pull-Up Voltage"?

"Pull-Up Voltage" is a Voltage

supplied from within an electronic
PULL-UP VOLTAGE control module through an internal
ECM
resistor which "pulls up" the signal
circuit contact on the connector of
+V the control input shown in this
PULL UP illustration.
RESISTOR
SWITCH OR The signal contact is held at this
SENSOR INPUT Pull-Up Voltage (high) except during
SIGNAL CIRCUIT the time that the sensor (or switch)
+V
SIG drives the signal to a low level (low).
GROUND The terms, "low" and "high" relate to
GND
the expected extreme values of the
signal input voltage level.

Question: Where are Pull-Up circuits used?

Pull-up circuits are used on most sensor and switch inputs of electronic controls. Frequency sensor inputs to a
control module do not typically have a "Pull-Up Voltage." One exception to this rule is the suspension cylinder
pressure sensor inputs to VIMS interface modules. These sensor inputs DO require a Pull-Up Voltage.

Some VIMS interface module frequency inputs can be programmed by the VIMS configuration software to have
a Pull-Up Voltage while others never use a Pull-Up Voltage. (Ref: SENR6059).

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Question: What Is The Purpose of "Pull-Up" Voltage"?

This voltage provides a known "signal" on the switch or sensor input for the electronic control. For example, the
control knows (by the computer software program within the control) that if the input is open (no sensor is present
or, the switch on this input is open) the "signal" on this input should be equal to the value of the Pull-Up Voltage.
If a PWM sensor belongs on this input, the control knows when there is no PWM oscillation because the input is
usually fixed at the Pull-Up Voltage value. This is the condition the control identifies as FMI 03-Voltage Shorted
High.

The opposite condition may occur on a signal input that is expected to be oscillating as from a PWM sensor but is
shorted to ground. Again, there will be no change in level or voltage value of the input so the control knows that
a signal input that is continuously held at ground (low) is abnormal. The control recognizes this condition as
FMI 04-Voltage Shorted Low.

Question: Under What Conditions Will I See "Pull-Up Voltage"?

When the sensor or switch is disconnected at the harness connector, the signal contact should be pulled up to the
value (high) of the pull-up circuit. When a voltmeter is connected between the signal contact and signal ground
contact on the harness connector (control side), the voltmeter should read the value of the Pull-Up Voltage.

Question: What Value Is "Pull-Up Voltage" to the Service Technician?

The purpose of Pull-Up Voltage is to allow an electronic control to determine what is happening on its signal
input in the outside world. This ECM design is of great value to the service technician, it allows a quick test of
the entire control input circuit. For example:

• If the sensor or switch is disconnected and the Pull-Up Voltage is measured to be the specified value, the
harness and control are very likely to be working as expected.

• If the sensor or switch is disconnected and the Pull-Up Voltage is measured to be ABOVE the specified value,
the failure is a harness short to a voltage source higher than the pull-up value or, the control has failed
internally.

• If the sensor or switch is disconnected and the Pull-Up Voltage is measured to be near or at ground (0 Volts),
the harness is likely to be open, or shorted to ground, or the control has failed internally.

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Question: How Much Voltage Can I Expect From Pull-Up Circuits?

This voltage is determined by the electronic control design and may vary between controls. Use the service
manual for the control to find the voltage. Pull-Up Voltage sometimes is the same value as the voltage source that
powers the sensor. Remember, Pull-Up Voltage is on the SIGNAL input to the control for a given sensor (or
switch) and most often HAS NO relationship to the voltage that POWERS the sensor. PWM sensors most often
have a Pull-Up Voltage value different than the voltage that powers them.

Analog sensors, as used with engine controls, most often have a Pull-Up Voltage that is the same as the voltage
that powers them. Typical values you can expect are 5V, 6V, 8V and 12V but can include other values also.

Question: What is Meant By Analog and Digital Sensors?

Analog sensors provide a signal that varies smoothly over the measured range such as a resistive fuel level sender
or engine oil pressure sensor as used with an engine control module. The value of the fuel sender is in Ohms and
is measured on the resistance scale of a multimeter. The signal of the oil pressure sensor is proportional to the
sensed pressure (condition) and can be measured with a DC voltmeter.

Digital sensors provide a signal that has only two voltage levels: at ground (low) or at some positive value (high)
and oscillates between these two levels. The actual value of the measured condition is proportional to that
condition and is represented by either the duty cycle (use duty cycle meter) or frequency (use frequency meter) of
the signal. The electronic control module knows (with internal software) what type of signal is expected on each
input and how to "read" the signal.

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 Electronic Technician Course Prerequisites

In order to complete all the software exercises in this course, the student must be able to demonstrate proficiency in basic
computer operations using Microsoft® Windows 95/98/NT/2000™, including the following tasks:

PC Operations
1. Start up and correctly shut down a PC.

2. Start, operate, save and exit software programs.

3. Operate the mouse or other pointing device using both buttons.

4. Using Microsoft® Windows Explorer: Create, delete and rename directories (folders); move, delete and
rename files; determine hard drive usage and available capacity. Arrange windows using the tile function.

5. Using Microsoft® Windows Explorer: copy files from a diskette or CD ROM drive to a hard drive.

6. Connect and operate external devices such as a power supply or a CD ROM drive using the Microsoft®
Windows 95/98/NT/2000™ installation function "Install Wizard."

7. Identify the current communications port in use and configure the port to enable external communications with
the PC.

8. Using the Copy Disk function, copy the entire contents on a diskette to another diskette.

9. Install programs from a CD ROM.

10. Navigate through and manipulate other Microsoft® Windows functions such as: task bar, pop-up start menu,
control panel and display functions.

11. Using data from the CAT ET Data Logger, create a spreadsheet in a program such as Excel or Lotus 123.
Adjust the format to accommodate the numbers, save and print the data.

Other Prerequisites
In order to complete the engine related exercises described in this course, the student must have completed courses, or
able to demonstrate proficiency in basic engine operations including the following subjects:

• Diesel governing systems

• Diesel fuel systems

• Air intake and exhaust systems

• Lubrication systems

• Cooling systems

• Basic electrical systems

• Engine diagnostics

To download a current version of this document, please check page 4 of the Newsletter for instructions.

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 Caterpillar Electronic Technician (Cat ET)
PC To Machine/Engine Connections
Communication Adapter II
Engine Electronic 207-6845 Universal 196-0055 Serial Cable (25 ft) *
Control Module (ECM) Data Link Cable (2 ft) or 225-5985 Parallel Cable (25 ft) **
160-0133 (discontinued) 160-0141 Serial Cable (25 ft) *** STW/E
160-0142 Serial Cable, short (10 ft) T

To PC Serial USB or
Service Tool
Parallel Port
Connector Communication
Adapter II
171-4400 (Group) 237-7547
Supports ATA CDL & CAN data links USB/Serial Adapter
* Included with Comm Adapter Group
** For use only on newer PC's without serial ports
*** For all PC's except IBM Think Pads and Compaq Computers

Engine Electronic
Communication Adapter I
Control Module (ECM)
139-4166 7X1425
Data Link Cable (18 ft) Serial Cable (4 ft) STW/E
T

PC Serial or USB Port

Service Tool
Connector
Communication
Adapter I
7X1700 (Group)
Supports ATA & CDL data links
(discontinued but still in use)