BASICELE ELECTRICIADAD Y SENSORES

Service Training MALAGA

MACHINE ELECTRONICS ELECTRONIC CONTROL SENSOR SUPPLY

OSCILLATOR

DUTY CYCLE

A C

SIGNAL

B

GROUND

AMPLIFIER THERMISTOR

Adolfo December 1997

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2

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

0 Time (C)

Time (D)

DC Signals

MACHINE ELECTRONICS

+

- 12V

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5

One Hertz

Time

MACHINE ELECTRONICS

0

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

0

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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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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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2

MACHINE ELECTRONICS

1

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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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21

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

T

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

°C

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

P

15

AUT

20

5

25 X100

R 24 V

0

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

L

74

- BODY UP SWITCH (AFTER 10 SECOND ACTIVATION)

SERV CODE

SERV CODE

030 MID

Page:

- 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

C

C

170

-2-

190 GA - 2

GA - 1

SERVICE

kPa

030 MID

-4-

tatle MILES

UNITS PERMAMENT LOAD COUNT ECONOMY SHIFT (NOT 777D)

-6-7-

L

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

2

12

13

3

4

5

6

7

8

9

(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

Page: SHIFT LEVER SWITCH

Page:

EPTC II NORMAL OPERATION

34 SELECT SPEED (UPSHIFT)

EPTC II D1

D2

STORE SHIFT

D3

10

SHIFT LEVER SWITCH GND VERIFY

11

2

12

13

3

4

5

6

7

8

CHECK TOS

9

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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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.

2

___

grid location

___

machine location (silouette).

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.

5.

___

grid location

___

machine location (silouette).

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

2

b)

3

c)

4

d)

5

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40

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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