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TECHNICAL PRESENTATION
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CATERPILLAR
MIN MAX RANGE HOLD
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MACHINE
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~V
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A ELECTRONICS
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COURSE
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FUSED
TABLE OF CONTENTS
COURSE DESCRIPTION............................................................................................................3
MODULE DESCRIPTION/OBJECTIVES..................................................................................4
ELECTRONIC COMPONENTS..................................................................................................6
INPUT COMPONENTS...............................................................................................................8
OUTPUT COMPONENTS.........................................................................................................36
ELECTRONIC CONTROLS......................................................................................................43
COURSE DESCRIPTION
This module is a review of the basic electrical and electronic principles needed by a technician to
understand and maintain the complex machine systems installed in Caterpillar products. The modules
do not teach specific machine systems unless otherwise stated in the lesson description.
Each module contains a quiz/skill test to measure the student's electrical/electronic skills and
knowledge. It is recommended that the pretest be completed prior to scheduling training. The pretest is
designed to evaluate each module of the course and may be used as a "skills/knowledge inventory" for
the evaluation of each student.
Pretest
• Administer the pretest.
• Do not answer questions regarding pretest content.
• Collect pretest, do not review or discuss test with students.
• Grade the pretest, but do not pass out scores.
• Use the pretest to evaluate each students knowledge prior to receiving instruction.
Posttest
• Each module lesson quiz/skill test will serve as a posttest for the individual modules.
• Have students exchange tests and review and discuss each question.
• Have students mark the incorrect responses.
• Collect all copies of the quizzes/skill tests and file for future reference.
A module description
A module objective
A module plan
A list of reference materials or job aids needed to present the module
A student handout section (if applicable)
A student quiz and a master copy of the quiz for the instructor (with answers)
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Miscellaneous Items:
ELECTRONIC
COMPONENTS
Input Devices
Output Devices
Controls
ACTION
ALARM
DISPLAY
DATA LINK
INPUT
COMPONENTS
AUTO RETARDER
CONTROL
INPUT
COMPONENTS
ENGINE
TRANSMISSION CONTROL
CONTROL
INPUT COMPONENTS
• SWITCHES
• SENDERS
• SENSORS
Input Components
Switches
This slide shows an engine oil pressure switch (arrow) located on the right
side of the engine. The pressure-type switch contacts are normally open
(engine not running). When the engine is running, the contacts close and
complete the ground circuit. If engine oil pressure drops to a level where
the contacts open, the operator will be alerted to a Category 3 warning
condition and instructed to shut the engine down safely.
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During normal operation, the level of the fluid (coolant) surrounds the
plastic sleeve of the switch and the switch (internally) provides a
grounded signal circuit to the main display module keeping the level alert
indicator OFF. If the fluid level drops below the probe, the switch will
sense the change and open the signal circuit causing the alert indicator to
begin flashing a warning condition.
This switch must be tested while installed in the machine and the system
powered (key on). Using a digital multimeter, measure the voltage on the
signal wire (at the connector). If the coolant level is within specification
(covering the plastic sleeve), the voltage on the signal wire should read
less than 1 volt DC indicating that the switch is functioning normal. If the
voltage level is greater than 1 volt DC and the fluid level is within
specification, the switch is defective.
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SENDER-TYPE
• 0 to 240 OHM
• 70 to 800 OHM
Senders
This slide shows a 0 - 240 ohm sender used to measure fuel level. The
sender (arrow) is located in the top of the fuel tank and measures the
depth of fuel in the tank. Two types of level senders are available for use
in the Caterpillar Monitoring System. One sender has an internal
resistance range between 0 and 90 ohms, and the other type has a
resistance range between 33 and 240 ohms. The depth of fuel in the tank
determines the output resistance which is measured by the main display
module. The main display module displays the fuel level on the gauge
cluster module. Additionally, the system has an alert indicator that will
flash a warning category if the level of fuel drops below 10% of tank
capacity.
If a failure occurs in the fuel level sender circuit, the main display module
will display MID, CID and FMI information. The information available
for the fuel system is: MID 30, CID 096, FMI 03. The probable causes
are:
- Sender
- Open ground
- Shorted signal to +Battery
- Open signal wire
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10
If a sender failure occurs, the main display module will alert the operator
to a Category 2 warning and log a fault in the main display module. The
gauge will read in the high temperature range. The following diagnostic
information will be stored in the display memory. The information
available for the torque converter temperature system is: MID 30, CID
177, FMI 04. The probable cause is:
Important for the The temperature sender operates on a negative temperature coefficient
technician to know (NTC) principle which results in a decrease in resistance when the
that a gauge driven measured temperature increases. Diagnostically, the only condition
by sender will that the control can determine is a high temperature (low resistance).
indicate low if the The result is a gauge operating in the high range. If the sender element
signal wire or the opened, the control could not determine if the measured temperature
sender is open was in the low (cold range) or the high resistance was caused by an
open circuit. The resulting indication would be a gauge operating at
the far left side of the scale.
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SENSOR-TYPES
• FREQUENCY
• PWM (DIGITAL)
• ANALOG
• ANALOG to DIGITAL
11
Sensors
This section will discuss the following types of input sensors: (1)
frequency sensors, (2) analog sensors, (3) digital sensors, and (4) a
combination of analog to digital sensors.
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12
Frequency Sensors
Two Basic Types Electronic control systems use various types of components for measuring
speeds. The two most common type sensors are identified as
1. Magnetic
2. Hall-Effect
(1) Magnetic and (2) Hall-Effect.
MAGNETIC FREQUENCY
SENSOR
13
A magnetic pickup may be checked for both static and dynamic operation.
With the pickup disconnected from the machine electrical harness, a
resistance reading of the pickup coil (measured between pins A and B)
should indicate a coil resistance of approximately 100 - 200 ohms. The
resistance value differs between pickup types, but an infinite resistance
measurement would indicate an open coil, while a zero reading would
indicate a shorted coil.
It is important to emphasize to the students that the air gap between the
gear tooth and the magnetic pickup determines the amplitude of the AC
signal being sent to the control. Consult the appropriate service manual
before installing.
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TRANSMISSION SPEED
OUTPUT
ROTATING REMOVE DC
AMP AMP
GEAR VOLTAGE LARGE
SMALL SMALL AC
SQUARE SQUARE SQUARE
WAVE WAVE WAVE
SENSING ELEMENT
('HALL CELL') HALL CELL
IN SLIP HEAD
14
The internal electronics of the sensor process the input and send larger
square wave pulses to the control.
Hall-Effect devices are designed for best results at zero air gap.
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15
A recommended procedure for checking the sensor is the use of the on-
board diagnostics to determine if the control is receiving the correct speed
input signal. If it is not, remove the sensor from the machine and visually
check the self-adjusting tip for damage. If the serviceability of the sensor
can not be determined, replace the sensor.
16
17
This slide shows a timing wheel and sensor. As each gear tooth passes
the cell, the sensing element sends a small signal to an amplifier. The
internal electronics average the signal and send the signal to a comparator.
If the signal is below average (gap) the output will be low, if the signal is
above average (tooth under cell) the output will be high.
Point out the differences in the width of the timing segments and their
patterns. The width of the segments are used to measure the "duty
cycle" (time on vs. time off) frequency and the tooth patterns are used
for timing orientation. The teeth and sensor generates a Pulse Width
Modulated (PWM) signal for the purpose of timing and a frequency
modulated output for speed measurement.
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COMPARATOR
SMALL SQUARE
WAVE
SENSING ELEMENT
('HALL CELL') HALL CELL
IN SLIP HEAD
18
Typical internal On the Electronic Unit Injection (EUI) system a unique tooth pattern on
schematic for a speed the timing reference gear allows the electronic control to determine
timing sensor crankshaft position, direction of rotation and rpm. As a tooth edge
approaches the Hall cell a signal is generated. The signal will be high
during the time that the tooth is under the slip head and will go low when
a gap between the teeth is present. The electronic control counts each
pulse and determines speed, memorizes the pattern (unique tooth pattern)
of the pulses and compares that pattern to a designed standard to
determine crankshaft position and direction of rotation.
This slide shows a typical speed timing signal generating a pulse width
modulation frequency output which is determined by the tooth pattern on
the rotating wheel.
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19
Digital Sensors
Note the physical size of a digital PWM sensor. It is important that the
student can identify the different types of electronic sensors. In most
cases, a digital sensor will be larger than an analog sensor because the
digital sensor contains the electronic components within the sensor body.
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V+ B+
VS GND
Signal
+8
20
This slide shows a digital temperature sensor. The ISO symbol indicates
that this type sensor can be used to monitor various machine conditions
(hydraulic, power train, coolant, etc.). The most important feature on the
graphic is the envelope representing the schematic symbol. This same
type symbol can be used for other types of sensors. The information
contained inside the schematic envelope helps the technician to determine
which type of sensor is being used. The following information may be
displayed inside the envelope:
➥
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ELECTRONIC
CONTROL
OSCILLATOR SENSOR
SUPPLY
DUTY
CYCLE
A
C SIGNAL
AMPLIFIER
B GROUND
THERMISTOR
21
Slide 21 is a This slide shows the internal components of a digital temperature sensor.
simplified schematic The key components are:
of the internal
components of a • A regulated sensor supply input voltage from an electronic control.
digital temperature
sensor. • An oscillator provides the signal carrier frequency. In this
particular application the internal oscillator supplies a carrier
frequency of approximately 5 kHz.
➥
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Stress the importance The serviceman should use the electronic system diagnostic information
of using the provided by the various electronic controls. If a serviceman suspects
diagnostic (based on diagnostic information) that a digital sensor is faulty, he can
information provided quickly verify if the sensor or sensor harness/connector is at fault. Using
by the electronic a Caterpillar multimeter 6V7070, a 7X1710 Probe Group and the
control. appropriate service manual module, the DC output voltage on the signal
wire can be measured and compared with the manual specification. If a
signal is present, but not within specification, the sensor should be
replaced. If no signal is present, it will be necessary to determine if the
supply voltage is present and if the ground circuit is good. If both are
within specification, the sensor should be replaced. If either measurement
is not within specification, it will be necessary to continue
troubleshooting.
The type of meter Additionally, a 9U7330 Digital multimeter can be used to determine the
used is not important. serviceability of a PWM sensor. The 9U7330 has the capability to
The student must measure DC voltage, carrier frequency and duty cycle. Using the 7X1710
know which type Probe Group and the 9U7330 leads connected between the signal wire
device he is (pin C) and ground (pin B) on the sensor connector, the serviceman can
troubleshooting and quickly analyze the condition of the sensor. The following measurements
what constitutes an would be typical for a PWM temperature sensor with the sensor
acceptable reading. connected to the control and the key switch turned ON.
Stress the need to
consult the • Pin A to Pin B -- Supply Voltage
appropriate service • Pin C to Pin B -- .7 - 6.9 DCV on DC volts scale
manual modules for • Pin C to Pin B -- 4.5 - 5.5 KHz on the KHz scale
specific • Pin C to Pin B -- 5% - 95% duty cycle on the % scale
measurements.
DC voltage may vary between the different types of PWM sensors, but
the carrier frequency must always be within the sensor specifications, and
the duty cycle should always be greater than 0% (usually between 5% -
10 %) on the low side and up to 95% on the high side (but never at
100%).
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22
Analog Sensors
Analog sensors differ from other types of sensors not only in the way they
function, but, also in the manner in which they are tested. On an
electrical schematic the sensor envelope looks the same as an envelope
for a digital sensor. The information that distinguishes an analog device
from other types is in the nomenclature describing the sensor supply
voltage and the sensor ground. An analog sensor will usually be
identified with a voltage indication on Pin A such as, +5V. The number
indicates the sensor power supply voltage being received from the
electronic control (the input voltage is regulated). The sensor ground on
Pin B will be identified by the nomenclature "analog return" or "return."
This indicates that the sensor is grounded back through the electronic
control and is not attached directly to frame ground.
The definition of an analog signal is: A signal that varies smoothly over
time, and in proportion to the measured parameter.
ENGINE
THERMISTER
CONTROL
AMPLIFIER A 5V
C SIGNAL (0 - 5V)
ANALOG
B RETURN
23
Slide 23 is a This slide shows the internal components of a typical analog temperature
simplified schematic sensor. The key internal components are (1) a thermistor to measure
of the internal temperature and (2) an OP amp device (operational amplifier) to provide
components of a an output signal that can vary from 0.2 to 4.8 DCV that is proportional to
analog temperature the temperature.
sensor.
The thermistor is a negative temperature coefficient (NTC) type device
Student is not where the resistance decreases as the temperature increases.
required to know the
internal operation of a Troubleshooting Analog Sensors
analog sensor. The
information is made The technician should use the electronic system diagnostic information
available for the provided by the various controls. If a technician suspects (based on
instructor to use in diagnostic information) that a analog sensor is faulty, he can quickly
explaining verify if the sensor or sensor harness/connector is at fault. Using a
troubleshooting 9U7330 digital multimeter, a 7X1710 Probe Group and the appropriate
procedures or service manual module, the DC output voltage on the signal wire can be
answering questions. measured and compared with the manual specification. If no signal is
present, it will be necessary to determine if the supply voltage is
present and if the ground circuit is good. ➥
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The signal voltage on Pin C will be different for each type sensor being
used. The output is proportional to the measured parameter (temperature,
pressure, etc.). Technicians should consult the appropriate service module
for individual sensor specifications.
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24
This slide shows a typical A-D pressure sensor. The pressure is measured
using the analog section and the signal is sent to a converter where it is
processed and converted to a digital (PWM) output and sent to a
electronic control.
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PWM OUTPUT
ANALOG TO CONTROL
SECTION DIGITAL CONVERTER
SIGNAL
V+
GROUND
SCHEMATIC DISPLAY
ENVELOPE GRAPHICS
25
This graphic shows two sections of a typical A-D sensor. The analog
section measures the parameter (pressure) and sends a signal to the digital
section (converter). The output from the digital section is a PWM signal
that is processed by the electronic control and then sent to an output
device, such as, a lamp or gauge, etc.
The schematic envelope does not identify the sensor as being an analog to
digital device. The information contained inside the envelope references
the sensor output. In this example, the output is a digital PWM signal.
The technician should troubleshoot this type device using the same
process as mentioned earlier for a digital (PWM) sensor. It is the sensor
output that determines the serviceability of the component.
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26
Ultrasonic Sensor
The ultrasonic fuel level reacts to the level of fuel in the tank. The sensor
emits an ultrasonic signal that travels up a guide tube in the tank. The
signal is reflected off a metal disk riding on the fuel and is directed back
to the sensor. The sensor measures the amount of time it takes for the
signal to leave the sensor, reflect off the disk, and return to the sensor.
The sensor has four contacts. The open or grounded status of contact
three on the connector tells the electronic control whether the sensor is
installed in a deep tank or a shallow tank.
Contact three should be open for a deep tank and grounded for a
shallow tank.
OUTPUT COMPONENTS
27
Output Components
Output devices are used to notify the operator of the status of the machine
systems. Caterpillar products use numerous output devices, such as:
display modules, action lamp and alarm, speedometers, tachometers,
payload lamps, gear position indicators, solenoids, etc.
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28
Main Display Modules
This slide shows the Caterpillar Monitoring System main display module
installed in the dash of a track-type tractor. The display area on the main
display module provides both digital and text information. The
information available on the display depends on the specific programmed
machine operating modes. Types of information that may be displayed
are:
The main display modules also use alert indicators to notify the operator
of abnormal machine conditions. The alert indicators will be discussed
later.
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29
This slide shows the main message center module for the Vital
Information Management System installed in an off-highway truck. The
message center provides the operator or technician with digital text
information on all measured machine parameters in addition to providing
warning information and a universal gauge function. The universal gauge
allows the operator or technician to select a specific parameter or to
monitor a troublesome parameter which has not exceeded its limit.
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30
The display data link is a six wire electrical harness that connects the main
display module to the other output display components, such as, the gauge
cluster module, speedometer/tachometer module, and message center
module. Since each of these output modules contain micro-processors,
they must communicate with each other in a digital data format.
Do not confuse the display data link with the Cat Data Link which
communicates with the various electronic control modules.
ALERT
INDICATOR
31
Alert Indicators
The type of alert indicators vary between the different monitoring systems
used on Caterpillar products. The monitoring system used on earlier
machines consisted of a "flashing" red LCD to alert the operator to an
abnormal condition. The Caterpillar Monitoring System continues to use
the same type of an indicator, while the VIMS uses a lamp.
This slide shows the alert indicator (arrow) as an internal lamp installed in
the main message center module of the VIMS. The location or type of
device used is not important. The alert indicators primary function is to
call the operators attention to an abnormal system condition.
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32
Action Lamp/Alarm
The action lamp and alarm are also intricate parts of the monitoring
systems installed in Caterpillar products. The action lamp is associated
with the alert indicator to notify the operator of a Category 2 warning.
The action alarm is also associated with the alert indicator and action
lamp to notify the operator of a Category 3 warning.
This slide shows a typical action lamp (arrow) installed in the dash of a
large track-type tractor equipped with the Caterpillar Monitoring System.
A photo of the action alarm is not shown. The alarm is typically located
behind the operator's seat or inside a panel out of view.
➥
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Depending on the type of machine and the systems installed, various other
types of output components can be used. The larger off-highway trucks
use payload lamps that are automatically turned ON by an electronic
control to notify the loader operator that the target weight of the truck has
been reached.
Also, VIMS equipped machines use a service lamp (located on the outside
of the machine) to notify non-operator personnel that the machine has an
active fault or condition.
ELECTRONIC
CONTROLS
33
Electronic Controls
34
This slide shows a typical control used for electronic engines. The inputs
associated with an engine ECM are typically analog modulated inputs that
operate on a DC voltage between 0 - 5 volts.
The ECM measures inputs from the various sensors, processes those
inputs and then provides an appropriate output to control specific engine
functions. Earlier engine ECMs contained "plug-in" personality modules
for programming engines values, logged faults, etc. Later ECMs use a
"flash" method of programming, using software and a data link.
This type of control does not use an external battery for memory back-up.
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35
This slide shows the main VIMS control module installed in a large
hydraulic excavator. The ECM is the "heart" of the VIMS monitoring
system and receives processed inputs from the various other electronic
controls over the CAT data link and provides the appropriate outputs.
36
Directions: Using electrical schematic SENR8577, identify the following electronic components. List
the component type (switch, analog, digital), indicate if it is an input, output or control, and list the part
number and schematic grid location for each component. Instructor needs to complete exercise to
conduct classroom discussion.
Directions: Using electrical schematic SENR8577, identify the following electronic components. List
the component type (switch, analog, digital), indicate if it is an input, output or control, and list the part
number and schematic grid location for each component.