Service Training

MALAGA

MACHINE ELECTRONICS

ELECTRONIC
CONTROL

OSCILLATOR SENSOR
SUPPLY

DUTY
CYCLE
A

C SIGNAL
AMPLIFIER
B GROUND
THERMISTOR

Adolfo
December 1997
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OHM'S LAW

R
E

I
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BASIC
ELECTRONIC
SIGNALS

MACHINE ELECTRONICS
DC SIGNALS

SINE WAVES

ANALOG SIGNALS
PULSE TYPE SIGNALS
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Fixed Positive Fixed Negative

+ 12V 0

7V
6V 6V
7V

0 - 12V
Time Time
(A) (B)
DC
Signals

MACHINE ELECTRONICS
+ Varying Positive +12V Positive Pulse

6V

0 0
Time Time
(C) (D)
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Time
One Hertz

0
WAVES
SINE
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ANALOG SIGNALS
DC volts +

MACHINE ELECTRONICS
0
Pressure ( kPa)
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DIGITAL SIGNALS
High

TWO DISTINCT

MACHINE ELECTRONICS
AMPLITUDE
LEVELS

Low
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PULSE WIDTH MODULATED

"DUTY CYCLE"
TIME ON vs TIME OFF
+ ON

MACHINE ELECTRONICS
0
OFF ONE PERIOD
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ELECTRONIC
COMPONENTS

Input Devices

MACHINE ELECTRONICS
Output Devices

Controls
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CATERPILLAR MONITORING SYSTEM
769D - 777D OFF-HIGHWAY TRUCKS
10

GAUGE CLUSTER TACHOMETER MESSAGE CENTER ACTION

MODULE MODULE MODULE LAMP

1F C kPa MilesKM RPM Liter SERV

CODE
... X10

ACTION
ALARM

DISPLAY
DATA LINK

MACHINE ELECTRONICS
CAT DATA LINK

INPUT
COMPONENTS
AUTO RETARDER
CONTROL
INPUT
COMPONENTS
ENGINE
TRANSMISSION CONTROL
CONTROL

1997 Caterpillar Inc.

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INPUT COMPONENTS
SWITCHES
SENDERS

MACHINE ELECTRONICS
SENSORS
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SENDER-TYPE
0 to 240 OHM

MACHINE ELECTRONICS
70 to 800 OHM
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SENSOR-TYPES
FREQUENCY
PWM (DIGITAL)

MACHINE ELECTRONICS
ANALOG
ANALOG to DIGITAL
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2
1
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MAGNETIC FREQUENCY
SENSOR
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TRANSMISSION SPEED

SMALL SIGNALS FROM

SENSING ELEMENT

OUTPUT

ROTATING REMOVE DC
GEAR AMP AMP
VOLTAGE SMALL AC LARGE
SMALL
SQUARE SQUARE SQUARE

MACHINE ELECTRONICS
WAVE WAVE WAVE

SENSING ELEMENT
('HALL CELL') HALL CELL
IN SLIP HEAD
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DIGITAL TEMPERATURE SENSOR

V+ B+
VS GND

MACHINE ELECTRONICS
Signal
+8
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ANALOG TEMPERATURE SENSOR

THERMISTER ENGINE
CONTROL

MACHINE ELECTRONICS
AMPLIFIER A 5V

C SIGNAL (0 - 5V)
ANALOG
B RETURN
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PWM OUTPUT
ANALOG TO CONTROL
SECTION DIGITAL CONVERTER

MACHINE ELECTRONICS
SIGNAL
V+
GROUND
SCHEMATIC DISPLAY
ENVELOPE GRAPHICS
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OUTPUT COMPONENTS

Main Display Module

Display Data Link

MACHINE ELECTRONICS
Alert Indicators
Action Lamp/Alarm
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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).

2 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.

___ grid location

___ machine location (silouette).

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

a) 2

b) 3

c) 4

d) 5

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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. 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

9. 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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