ElectronicComponent INPUT, OUPUT

Service Training SEGV3002
Course Module July 1997
TECHNICAL PRESENTATION
TRUE RMS MULTIMETER

FLUKE 87
AUTO DC
0 0 00
0 1 2 3 4 5 6 7 8 9 0
V
± 4
CATERPILLAR
MIN MAX RANGE HOLD
REL ∆ Hz
Peak Min Max
Ω
MACHINE
---
mV
---
V
~V
mA
A ELECTRONICS
µA
OFF
COURSE
A mA µA COM V-Ω
400mA MAX
FUSED
10A MAX 1000V MAX

FUSED
MODULE TWO: ELECTRONIC

COMPONENTS
SEGV3002 -2- Module Two
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TABLE OF CONTENTS
COURSE DESCRIPTION............................................................................................................3
MODULE DESCRIPTION/OBJECTIVES..................................................................................4
LESSON PLAN ............................................................................................................................5
ELECTRONIC COMPONENTS..................................................................................................6
INPUT COMPONENTS...............................................................................................................8
OUTPUT COMPONENTS.........................................................................................................36
ELECTRONIC CONTROLS......................................................................................................43
MODULE TWO QUIZ...............................................................................................................48

SEGV3002 -3- Course Description
7/97
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.
Suggest the following procedure:
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.
The course is designed as several modules. The current modules are:
Module 1: Basic Electrical and Electronic Principles (SEGV3001)

Module 2: Electronic Components (SEGV3002)
Module 3: Wire Maintenance (SEGV3003)
Module 4: Electrical Schematics (SEGV3004)
Module 5: Machine Electrical and Electronic Systems, Diagnostic Tooling and Troubleshooting
Procedures (SEGV3005)
Additional Support Information:
List of Acronyms and Glossary of Electrical/Electronic Terms (SEKV3001)
Machine Electronic Course Pretest (SEBV3001)
Machine Electronic Course Pretest Answers (SEEV3001)
Each module contains the following:
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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Module Two MODULE TWO: ELECTRONIC COMPONENTS

Time: 4 Hours Module Two Description
This module covers the various electrical and electronic components

installed on Caterpillar products. The information provides the student
with the necessary background knowledge needed to understand and
perform the tasks associated with diagnosing and troubleshooting
electrical and electronic components and associated systems.
Presentation Method Lecture
Objectives Module Two Objectives
After completion of this module the student will be able to:
1. Given an electrical schematic of a 785B Truck identify the input,

output and controls on a quiz.
Note: A different model machine electrical schematic may be
substituted for a 785B. It will be necessary to develop a new quiz
for the appropriate model being used.
Pass examples of 2. Explain the function and operation of a two-state switch, an

components to analog sensor, a digital sensor, a magnetic-type speed sensor,
students during and a Hall Effect speed sensor on a quiz.
lecture
Module Two Reference Materials and Job Aids
Special tooling required: None

Job Aids: Collect various switches, senders and sensors to be used in
class during slide presentation.
Service Literature Required:
Schematic--785B Truck With VIMS Electrical System............SENR8577
Miscellaneous Items:
Duplicate Materials Vital Information Management System....................................SENR6059

and Quiz EPTCII for ICM Transmissions................................................SENR5666
Electronic Troubleshooting 3512 and 3516 EUI Engine..........SENR5597
"Getting Started in Electronics" (Radio Shack)..........................276-5003
Quiz Located at end of module.

Student Materials (if included) located at end of module.
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Module Two Module Lesson Plan
Lecture and Slide Presentation (Slides 1 through 36)

Demonstration
A. Electronic Component Introduction (Slides 1 and 2)
B. Input Components (Slides 3 through 26)

1. Introduction
2. Switches
3. Senders
4. Sensors
C. Output Components (Slides 27 through 32)

1. Main Display Modules
2. Display Data Link
3. Alert Indicators
4. Action Lamp/Alarm
5. Other Related Components
D. Electronic Controls (Slides 33 through 36)

1. Engine Control Module
2. Main VIMS Module
3. Electronic Programmable Transmission Module
E. Administer Quiz (Located at end of module two text)

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ELECTRONIC
COMPONENTS
Input Devices
Output Devices
Controls
Introduction Electronic Components
Caterpillar machine electronics systems operate similar to many other

systems on the market. Although Caterpillar machines use a variety of
electronic controls, the basic operating technologies are the same. Each
electronic control requires certain types of input devices to feed electronic
information to the control for processing. The control processes the input
information and then sends appropriate electronic signals to various types
of output devices, such as, solenoids, indicator lights, alarms, etc.
The technician needs only to be able to identify the various types of

controls used on Caterpillar machines. Most controls are fabricated so
access to the internal electronic components is not necessary.
The technician will need a thorough understanding of the different types

of input and output devices in addition to being able to perform the
necessary diagnostic troubleshooting process associated with each
individual control’s internal diagnostic capabilities.
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CATERPILLAR MONITORING SYSTEM

769D - 777D OFF-HIGHWAY TRUCKS
GAUGE CLUSTER TACHOMETER MESSAGE CENTER ACTION

MODULE MODULE MODULE LAMP
1F °C kPaMiles KM RPM Liter SERV

CODE
. .. X10
ACTION
ALARM
DISPLAY
DATA LINK
CAT DATA LINK
INPUT
COMPONENTS
AUTO RETARDER
CONTROL
INPUT
COMPONENTS
ENGINE
TRANSMISSION CONTROL
CONTROL
© 1997 Caterpillar Inc.
This slide shows a block diagram of the Caterpillar Monitoring System

installed in off-highway trucks. The diagram shows the various input
components, output components, and controls used by the off-highway
trucks to monitor the health of the various machine systems.
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INPUT COMPONENTS
• SWITCHES
• SENDERS
• SENSORS
Input Components
Most input devices used on Caterpillar machine electronic systems are

switches, senders or sensors. The technician must be able to identify each
device, understand the operation, and know how to use diagnostic test
equipment to determine the correct operation of each component.
Examples of each type of input device will be discussed in this section.
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Switches
The Caterpillar Monitoring System uses several different types of

switches to monitor machine conditions. They all have similar functions
and are often referred to as "two state" devices (on or off). They provide
an open input or a grounded input to a electronic control. Most
technicians are familiar with the older Electronic Monitoring System
(EMS) components and will recognize the similarities between the EMS
inputs and the newer systems, such as the Caterpillar Monitoring System.
The following slides show examples of some of the switch-type inputs

used on current electronic systems.
SEGV3002 - 10 - Module Two
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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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This slide shows a typical rocker-type switch (arrow) mounted on a panel

on the right side of the cab. This particular switch is used by the operator
to select certain operational modes for display on the main display
module.
The switch is a momentarily ON switch, and the contacts are normally

open. When the switch is activated (pressed) the signal wire provides a
ground to the main control module allowing the operator to access the
selected mode.
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This slide shows a recently developed electronic switch that is sometimes

used to monitor the engine coolant level. Its design and operation differ
from other types of level switches. This type of switch requires a
+8 DCV input from the main display module for operation.
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.
The switch probe is covered by a plastic sleeve. Do not remove the

plastic sleeve. The sleeve is necessary for proper switch operation.
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
The Caterpillar Monitoring System uses two different types of senders to

provide inputs to the main display module. They are identified as:
0 to 240 ohm senders, and 70 to 800 ohm senders.
0 to 240 ohm senders: These senders measure a specific system

resistance value which corresponds to a specific system condition. A
typical system using this type of sender is the fuel level. The output
resistance is measured at the main display module and the value
corresponds to the depth of fuel in the tank. The main display module
calculates the resistance and displays the output on one of the gauges
in the gauge cluster module. The 0 to 240 ohm sender may be
programmed to operate a gauge, an alert indicator, or both a gauge
and alert indicator.
The 0 to 240 ohm sender may only be used on Contacts 9 and 18 of

the main display module.
➥
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70 to 800 ohm senders: These senders measure a specific system

resistance value which corresponds to a specific system condition. A
typical system using this type of sender is a temperature or similar
system with the same operating parameters. The output resistance is
measured at the main display module, and the value corresponds to
the temperature of the fluid (oil, coolant, or hydraulic) being
measured. The main display module calculates the resistance and
displays the output on one of the gauges in the gauge cluster module.
The 70 to 800 ohm sender may be programmed to operate a gauge, an
alert indicator, or both a gauge and alert indicator.
The 70 to 800 ohm sender may only be used on Contacts 8, 10, 28

and 38 of the main display module.
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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
This slide shows a resistive-type sender which is used to sense fluid

temperatures. The resistance of the sender is typically in the range of 70
to 800 ohms. The resistance output varies with the temperature of the
fluid and the signal is sent to the main display module for display on the
gauge cluster module.
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:
- Signal circuit is shorted to ground
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
Sensors are used to measure physical parameters like speed, temperature,

pressure, and position. An electronic sensor converts a physical
parameter to an electronic signal. The electronic signal is proportional to
the physical parameter.
On Caterpillar electronic systems, sensors are used to monitor machine

systems that are constantly changing. The electronic signal represents the
measured parameter. The signal is modulated in one of three ways.
Frequency modulation represents the parameter as a frequency level.
Pulse width modulation (digital) represents the parameter as a duty cycle
between 0 to 100%. Analog modulation represents a parameter as a
voltage level.
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.
The type of sensor used is determined by engineering. On a system where

slower speeds are not critical, a magnetic pickup would used. On systems
where the measurement of slower speeds is essential, a Hall-Effect type
sensor would be used.
An example of a system using a magnetic pickup speed sensor would be

measuring the engine speed to be displayed on a tachometer. Speeds
below 600 rpm are not critical, where as, measuring RPM for the purpose
of timing an electronic engine requires speed measurements down to 0
rpm. In this particular case, a Hall-Effect type sensor would be used.
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MAGNETIC FREQUENCY
SENSOR
13
Magnetic Pickup Magnetic Pickup
A passive magnetic frequency-type sensor converts mechanical motion to

an AC voltage. A typical magnetic pickup consists of a coil, pole piece,
magnet and housing. The sensor produces a magnetic field that, when
altered by the passage of a gear tooth, generates an AC voltage in the coil.
The AC voltage is proportional to speed. The frequency of the AC signal
is exactly proportional to speed (RPM).
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
SMALL SIGNALS FROM

SENSING ELEMENT
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
Hall-Effect Sensor Hall-Effect Sensor
Some Caterpillar electronic systems use a Hall-Effect sensor for detecting

magnetic fields. The electronic transmission control and the electronic
unit injection system use this type of a sensor to provide pulse signals for
determining transmission output speed and the timing of the engine. Both
type sensors have a "Hall cell" located in a slip head on the tip of the
sensor. As a gear tooth passes the "Hall cell" the change in the magnetic
field produces a small signal which is sent to an amplifier in the sensor.
The internal electronics of the sensor process the input and send larger
square wave pulses to the control.
Typical construction of a Hall-Effect sensor. The sensing element is

located in the slip head and is extremely accurate because it's output
amplitude and phase are not speed dependent. It operates down to 0 RPM
over a wide temperature operating range. The drawing above shows some
of the key components of a Hall-Effect sensor.
Hall-Effect devices are designed for best results at zero air gap.
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15
Transmission Output Transmission Output Speed Sensor (TOS)

Speed Sensor
The transmission output speed sensor is a Hall-Effect device. The "Hall
cell" in the slip head detects a magnetic field when a gear tooth passes
and sends a small signal to an internal amplifier circuit in the sensor
where the DC voltage is removed, leaving only an AC voltage. The AC
signal (voltage) is sent to another internal amplifier which produces a
larger square wave output signal on pin “C” of the connector.
Diagnostically troubleshooting a Hall-Effect sensor is difficult because of

the type connector used on Caterpillar electronic systems. The connector
is a MS type (Military Specification) on the sensor and prevents the use of
the 7X1710 Probe Group for testing the sensor dynamically.
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.
Typically a self-adjusting slip head speed sensor will not fail

intermittently. It will be serviceable or defective.
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16
Speed Timing Sensor Speed Timing Sensor
Speed sensors on an electronically controlled engine measure engine

speed and timing. The speed of the gear is sensed by measuring the
magnetic field change when a gear tooth passes. Engine timing
corresponds to a tooth edge. This slide shows two different types of
speed timing sensors. Their operational characteristics are the same.
Speed timing sensors are designed specifically for "timing" electronic

injected engines. Their internal operational functions differ from other
frequency measuring devices.
Those differences will be explained in the next slide.

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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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SPEED TIMING SENSOR
SMALL SIGNALS FROM

SENSING ELEMENT AVERAGING
CIRCUIT
AVERAGE DC
VOLTAGE
OUTPUT
ROTATING
AMP
GEAR LARGE SQUARE
WAVE
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
Digital sensors on Caterpillar electronic systems utilize a method called

pulse width modulation (PWM) to provide the variable electronic input
needed by some controls. The ratio of electronic on-time to off-time is
varied at a frequency higher than the component can follow mechanically.
This results in an averaging of the on-off pulses which, in turn, results in a
variation in electrical voltage or current and the resulting force. The
requirements of each application will determine the selection of each
device. Digital sensors are used to measure a variety of applications, such
as position, velocity, force, pressure, etc. For this discussion on digital
PWM sensors, a PWM temperature sensing device will be used. All
PWM sensors perform the same basic function.
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:
SUPPLY The input voltage required for sensor operation can

be listed in many forms, such as:
B+, +B, +Battery = Supply voltage to the sensor is

being supplied by the machine batteries.
+8 = Indicates that the sensor is receiving a voltage

potential of 8 volts. The +8 is used as an example.
Some controls provide other voltage levels.
➥
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V+ = The supply voltage to the sensor is being

supplied from a source other than the machine
batteries. The technician needs to trace the sensor
supply source to the electronic control to determine
sensor supply voltage.
GROUND The use of the term "ground" inside the schematic

sensor envelope is significant to the technician.
Digital sensors (generally) are grounded to the
machine frame, usually in close proximity to the
sensor. It is also a means of identifying which type
sensor is used.
An analog sensor envelope will not use the term

"ground" in the envelope. It will generally
display the term(s) ANALOG RETURN, OR RETURN.
SIGNAL The term "signal" identifies the output lead of the

sensor. The signal wire supplies the parameter
information to the electronic control module for
processing.
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DIGITAL TEMPERATURE SENSOR
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.
• A thermistor (sensor) senses the monitored parameter and provides

a resistive input to an amplifier.
• An amplifier output controls the base of a transistor which

generates a duty cycle output measured in percent of time the
transistor is turned ON versus OFF.
➥
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Troubleshooting Digital Type sensors
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.
An analog sensor output represents only a DC voltage in proportion to the

measured parameter, usually between 0 and 5 volts. The sensor can also
be identified by its smaller size. The sensor contains only a portion of the
electronic components needed to display an analog signal, the remaining
components are located in the electronic control.
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ANALOG TEMPERATURE SENSOR
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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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 following measurements would be typical for an analog temperature

sensor with the sensor connected to the control and the key switch turned
ON.
• Pin A to Pin B -- Regulated 5.0 DCV input from the control

• Pin C to Pin B -- 1.99 - 4.46 DCV from the sensor
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
Analog to Digital Sensors
An analog to digital type sensor is a device that incorporates both analog

and digital electronics. The use of an analog to digital sensor is dictated
by the specific electronic control that is processing the information.
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.
7/97
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 graphic display symbol is used to identify the system being

monitored. In this example, the system is "brake air pressure."
Troubleshooting Analog to Digital Sensors
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.
7/97
26
Ultrasonic Sensor
Some Caterpillar machines are equipped with an ultrasonic sensor. This

type of sensor is used on fuel systems and replaces older types of sensors
that used a resistive sending unit inside the fuel tank.
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.
Troubleshooting procedures for the ultrasonic sensor would be the same

as those used for other PWM sensors. The ultrasonic sensor can not be
tested off the machine. It must be installed in a fuel tank to be tested.
7/97
OUTPUT COMPONENTS
• Main Display Module

• Display Data Link
• Alert Indicators
• Action Lamp/Alarm
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.
7/97
28
Main Display Modules
Caterpillar machines use many different types of display modules to

provide the operator and technician with information. Two examples of
display modules are: Caterpillar Monitoring System Display Module and
the Vital Information Management System Display Module.
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:
- Row of six digits (with decimal point between certain digits)
- Six text symbols (°C, kPa, Miles, km, rpm, Liter)
- Display SERV CODE
- Times 10 (x10) symbol (rpm)
- Service meter symbol (hourglass)
The main display modules also use alert indicators to notify the operator
of abnormal machine conditions. The alert indicators will be discussed
later.
7/97
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.
7/97
°C kPaMiles KM RPM Liter SERV

1F . ..
CODE
X10
DISPLAY DATA LINK
30
Display Data Link
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.
The following is a brief description of each connector contact.
- Contact No. 1 +9V DC input

- Contact No. 2 Ground
- Contact No. 3 Display Clock (digital input)
- Contact No. 4 Display Data (digital input)
- Contact No. 5 Display Load (digital input)
- Contact No. 6 Harness Code input
7/97
ALERT
INDICATOR
ENGINE TEMP [135]

60 Deg F
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.
7/97
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.
➥
7/97
Other Output Components
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.
Additionally, some electronic controls can remotely operate solenoids (as

output devices) to provide lubrication, engine shut-down, etc.
When explaining the operation of electronic controls, it is important for

the technician to understand that it takes three functions for a system to
perform accurately. The control must receive the correct input signal
from an input device, accurately process that signal, and then provide
the correct system output.
7/97
ELECTRONIC
CONTROLS
33
Electronic Controls
Electronic control modules (ECM) are sophisticated computers. They

contain electronic power supplies, central processing units, memory
sensor inputs. They communicate with other electronic controls over a bi-
directional data link.
Most controls used on Caterpillar electronic systems use three types of

inputs. They are switch-type which measures the state of a switch (open
or grounded), analog-type which measures the amplitude of a signal
(generally between 0 - 5 volts) and a digital-type which measures a
frequency (speed) or the pulse width of a periodic signal.
The type of control used is determined by engineering and is based on the

types of inputs and outputs. Most controls are identified by a term called
"drivers" which identifies the output characteristics, such as a current and
voltage drivers.
7/97
34
Types of Electronic Controls
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.
7/97
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.
This module requires a 3 volt lithium battery (external) to provide

memory back-up when the machine disconnect switch is opened.
7/97
36
This slide shows the Electronic Programmable Transmission Control

(EPTCII) module used by large mining trucks. The ECM communicates
with the engine control to provide smoother "clutch engagement" by
momentarily lowering engine speed when a clutch solenoid is energized.
7/97 Instructor Copy
Quiz
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.
Component Type In/Out/Cont Part Number Grid Loc

1. Transmission Speed Sender
2. Engine Control
3. Atmospheric Pressure Sensor
4. Right Hoist Screen Switch
5. VIMS Interface Module #2
6. Right Turbo Inlet Pressure
7. Lube Solenoid
8. Green Payload Monitor Lamp L.H.
9. Left Rear Brake Oil Temp
10. Cylinder Head Solenoid 12
11. Aftercooler Level
12. Upshift Solenoid
13. Body Up Sensor
14. Torque Converter Inlet Filter
15. Left Rear Strut Sensor
Directions: Briefly explain the principle operation of the following components:
16. Aftercooler Level Sensor:________________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
17. Engine Magnetic Speed Pick-up:___________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
18. R.H. Turbo Inlet Pressure Sensor:__________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
19. Torque Converter Inlet Filter:_____________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
20. Transmission Output Speed Sensor:________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________
7/97 Student Copy
Quiz
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.
Component Type In/Out/Cont Part Number Grid Loc

1. Transmission Speed Sender
2. Engine Control
3. Atmospheric Pressure Sensor
4. Right Hoist Screen Switch
5. VIMS Interface Module #2
6. Right Turbo Inlet Pressure
7. Lube Solenoid
8. Green Payload Monitor Lamp L.H.
9. Left Rear Brake Oil Temp
10. Cylinder Head Solenoid 12
11. Aftercooler Level
12. Upshift Solenoid
13. Body Up Sensor
14. Torque Converter Inlet Filter
15. Left Rear Strut Sensor
Directions: Briefly explain the principle operation of the following components:
16. Aftercooler Level Sensor:________________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
17. Engine Magnetic Speed Pick-up:___________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
18. R.H. Turbo Inlet Pressure Sensor:__________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
19. Torque Converter Inlet Filter:_____________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________.
20. Transmission Output Speed Sensor:________________________________________________

_____________________________________________________________________________
_____________________________________________________________________________

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Service Training SEGV3002

Course Module July 1997

TRUE RMS MULTIMETER

10A MAX 1000V MAX

MODULE TWO: ELECTRONIC

LESSON PLAN ............................................................................................................................5

MODULE TWO QUIZ...............................................................................................................48

Suggest the following procedure:

The course is designed as several modules. The current modules are:

Module 1: Basic Electrical and Electronic Principles (SEGV3001)

Each module contains the following:

Module Two MODULE TWO: ELECTRONIC COMPONENTS

This module covers the various electrical and electronic components

Presentation Method Lecture

Objectives Module Two Objectives

After completion of this module the student will be able to:

1. Given an electrical schematic of a 785B Truck identify the input,

Pass examples of 2. Explain the function and operation of a two-state switch, an

Special tooling required: None

Service Literature Required:

Schematic--785B Truck With VIMS Electrical System............SENR8577

Duplicate Materials Vital Information Management System....................................SENR6059

Quiz Located at end of module.

Module Two Module Lesson Plan

Lecture and Slide Presentation (Slides 1 through 36)

B. Input Components (Slides 3 through 26)

C. Output Components (Slides 27 through 32)

D. Electronic Controls (Slides 33 through 36)

E. Administer Quiz (Located at end of module two text)

Introduction Electronic Components

Caterpillar machine electronics systems operate similar to many other

The technician needs only to be able to identify the various types of

The technician will need a thorough understanding of the different types

CATERPILLAR MONITORING SYSTEM

GAUGE CLUSTER TACHOMETER MESSAGE CENTER ACTION

1F °C kPaMiles KM RPM Liter SERV

CAT DATA LINK

© 1997 Caterpillar Inc.

This slide shows a block diagram of the Caterpillar Monitoring System

Most input devices used on Caterpillar machine electronic systems are

The Caterpillar Monitoring System uses several different types of

The following slides show examples of some of the switch-type inputs

This slide shows a typical rocker-type switch (arrow) mounted on a panel

The switch is a momentarily ON switch, and the contacts are normally

This slide shows a recently developed electronic switch that is sometimes

The switch probe is covered by a plastic sleeve. Do not remove the

The Caterpillar Monitoring System uses two different types of senders to

0 to 240 ohm senders: These senders measure a specific system

The 0 to 240 ohm sender may only be used on Contacts 9 and 18 of

70 to 800 ohm senders: These senders measure a specific system

The 70 to 800 ohm sender may only be used on Contacts 8, 10, 28

This slide shows a resistive-type sender which is used to sense fluid

- Signal circuit is shorted to ground

Sensors are used to measure physical parameters like speed, temperature,

On Caterpillar electronic systems, sensors are used to monitor machine

The type of sensor used is determined by engineering. On a system where

An example of a system using a magnetic pickup speed sensor would be

Magnetic Pickup Magnetic Pickup

A passive magnetic frequency-type sensor converts mechanical motion to

SMALL SIGNALS FROM

Hall-Effect Sensor Hall-Effect Sensor

Some Caterpillar electronic systems use a Hall-Effect sensor for detecting

Typical construction of a Hall-Effect sensor. The sensing element is