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Service Training MALAGA
MACHINE ELECTRONICS ELECTRONIC CONTROL SENSOR SUPPLY
OSCILLATOR
DUTY CYCLE
A C
SIGNAL
B
GROUND
AMPLIFIER THERMISTOR
Adolfo December 1997
Page:
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
+
Page: 7
DIGITAL SIGNALS High
AMPLITUDE LEVELS
Low
MACHINE ELECTRONICS
TWO DISTINCT
Page: 8
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
Page:
CATERPILLAR MONITORING SYSTEM 769D - 777D OFF-HIGHWAY TRUCKS
SENSOR-TYPES FREQUENCY PWM (DIGITAL) ANALOG ANALOG to DIGITAL
MACHINE ELECTRONICS
• • • •
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17
2
MACHINE ELECTRONICS
1
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18
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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20
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
Page:
23
MACHINE ELECTRONICS
Page: 24
ANALOG TEMPERATURE SENSOR ENGINE CONTROL
THERMISTER
T
A C B
5V SIGNAL (0 - 5V) ANALOG RETURN
MACHINE ELECTRONICS
AMPLIFIER
Page: 25
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
Page: 29
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)
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
Page:
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
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
Page:
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
Page:
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
