Service Training
MALAGA
777D Off Highway Truck
MESSAGE CENTER ACTION
GAUGE CLUSTER TACHOMETER MODULE LAMP
MODULE MODULE
°C kPa Miles KM RPM Liter
SERV
... CODE
X10
ACTION
ALARM
DISPLAY
DATA LINK
CAT DATA LINK
INPUT
COMPONENTS
AUTO RETARDER
CONTROL
INPUT
TRANSMISSION ENGINE COMPONENTS
CONTROL CONTROL
XI. CAT MONITORING SYSTEM
1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
Adolfo
August 1997
Page:
CATERPILLAR MONITORING SYSTEM
XI-1
MESSAGE CENTER ACTION
GAUGE CLUSTER TACHOMETER MODULE LAMP
MODULE MODULE
°C kPa Miles KM RPM Liter
SERV
... CODE
X10
ACTION
ALARM
CHAPTER : CAT MONITORING SYSTEM
DISPLAY
DATA LINK
777D Off Highway Truck
CAT DATA LINK
INPUT
COMPONENTS
AUTO RETARDER
CONTROL
INPUT
TRANSMISSION ENGINE COMPONENTS
CONTROL CONTROL
Page:
CATERPILLAR MONITORING SYSTEM
XI-2
MAIN DISPLAY
FOUR GAUGE ALERT
CLUSTER MODULE INDICATORS
ACTION LAMP
CHAPTER : CAT MONITORING SYSTEM
P
15 AUT
10 20
777D Off Highway Truck
5
25
X100
R
0 MPH 30 44
24 V
km/h
SPEEDOMETER /
TACHOMETER MODULE
MESSAGE CENTER MESSAGE
MODULE DISPLAY
Page:
XI-3
DASH INDICATORS
LEFT TURN 15 RIGHT TURN
10 20
BODY UP ACTION LAMP
CHAPTER : CAT MONITORING SYSTEM
5
25
X100 SECONDARY
REVERSE R STEERING
777D Off Highway Truck
0 MPH 30
24 V km/h
HIGH BEAM RETARDER
Page:
FOUR GAUGE
CLUSTER MODULE
XI-4
BRAKE OIL
TEMPERTURE
ENGINE
COOLANT
TEMPERATURE
CHAPTER : CAT MONITORING SYSTEM
777D Off Highway Truck
FUEL
LEVEL
SISTEM
AIR PRESSURE
The four systems monitored by the Four Gauge Cluster Module are:
- Engine Coolant Temperature
Maximum temperature: 107 ° C (Data link)
- Brake Oil Temperature - Maximum temperature 121 ° C
- System Air Pressure - Minimum pressure 70 Psi.
- Fuel Level - Minimum 8 %.
Page:
XI-5
SPEEDOMETER / TACHOMETER
MODULE
15
10 20 RPM
CHAPTER : CAT MONITORING SYSTEM
5 25
X100
777D Off Highway Truck
MPH
0 km/h 30
ACTUAL
GROUND SPEED GEAR
777D Off Highway Truck
CHAPTER : CAT MONITORING SYSTEM
MESSAGE CENTER MODULE
PARKING BRAKE ON BATTERY VOLTAGE
BRAKE CYLINDER OVERSTROKE\ "R" TERMINAL Hz
ENGINE OIL TORQUE CONVERTER OIL
PRESSURE / BRAKE OIL ENGINE MAINTENACE
TEMPERATURE REQUIRED (777D ONLY)
ALERT P
INDICATORS
!
CHECK ENGINE
AIR FILTER LIGHT
RESTRICTION
SERV
LOSS OF
44
CODE
STEERING LOSS OF
FLOW COOLANT
FLOW
MESSAGE TRANMISSION
FILTER
DISPLAY RESTRICTION
ACTIVE CODE
INDICATOR
There are 10 Alert Indicators, which are:
- Engine Oil Pressure - Minimum pressure: LI 6.4 Psi and HI 36 Psi.
- Parking Brake ON or Parking Brake Master Cylinder Overstroke.
- TC Oil Temperature /Brake Oil Temperature - Maximum Temperature 121°
- Battery Charging- - Mininmum Voltage 23 Volts
- Minimum "R" Terminal Frequency 95 Hz/ 20V
- Engine Maintenance Required (777 D only) Fuel Filter Restriction, Add Oil.
- Air Filter Restriction - Maximum Restriction: 25 " of H20 (3500)
- Steering Flow
- Transmision Oil Filter restricted - Maximum differential pressure 36 Psi
- Engine Coolant Flow
- Check Engine - MID 036 Fault Codes or Events.
Page: XI-6
Page:
SECONDARY STEERING AUTO
AND BRAKE RETRACTION RETARDER
XI-7
AUT
LIGHTS TRACTION CONTROL
SYSTEM TEST
CHAPTER : CAT MONITORING SYSTEM
OPERATOR SCROLL
777D Off Highway Truck
THROTTLE
BACK-UP
ETHER AIR
STARTING AID CONDITIONING
777D Off Highway Truck
CHAPTER : CAT MONITORING SYSTEM
INPUT COMPONENTS
• SWITCHES
• SENDERS
• SENSORS
Page: XI-8
Page:
SWITCH - TYPE INPUTS
XI-9
-UNCOMMITTED SWITCH INPUTS:
OPERATE TEN ALERT INDICATORS
NORMALLY GROUNDED & INDICATOR OFF
FLASHES IF ABNORMAL CONDITION EXISTS
CHAPTER : CAT MONITORING SYSTEM
-PROGRAMMING SWITCH INPUTS:
777D Off Highway Truck
HARNESS CODES (6 INPUTS OPEN OR GROUNDED)
IDENTIFIES SPECIFIC MACHINE MODEL
-SERVICE SWITCH INPUTS:
MACHINE SETUP
MODE OF OPERATION
DIAGNOSTIC FUNCTIONS
Page:
XI-10
SENDER - TYPE INPUTS
- 0-240 OHM SENDERS:
CONTACTS 9 & 18 OF MAIN DISPLAY MODULE
OPERATES GAUGE, ALERT INDICATOR OR BOTH
CHAPTER : CAT MONITORING SYSTEM
FUEL LEVEL SENDER (18)
777D Off Highway Truck
-70- 800 OHM SENDERS:
CONTACTS 8, 10, 28, 38 OF MAIN DISPLAY MODULE
OPERATES GAUGE, ALERT INDICATOR OR BOTH
HYD OIL TEMP (10), T.C. TEMP (28)
Page:
XI-11
SENSOR - TYPE INPUTS
- PWM (DIGITAL):
DUTY CYCLE SIGNAL
OPERATES GAUGE
CHAPTER : CAT MONITORING SYSTEM
T.C. OIL TEMP, BRK AIR PRESS, BRK OIL TEMP
777D Off Highway Truck
FUEL LEVEL(ULTRASONIC) (NOT 777D)
D.C. SIGNAL
-FREQUENCY SENSORS:
AC FREQUENCY (Hz) SIGNAL
OPERATES SPEEDOMETER/TACHOMETER MODULE
ENGINE SPEED, XMS OUTPUT SPEED
Page:
WARNING OPERATION
XI-12
ACTION LAMP
ALERT INDICATORS
P
15 AUT
10 20
5
25
X100
R
0 MPH 30 44
24 V
km/h
CHAPTER : CAT MONITORING SYSTEM
777D Off Highway Truck
WARNINGS
LEVEL 1 : ALERT INDICATOR FLASHES (10 Hz)/GAUGE IN RED
LEVEL 2 : ALERT INDICATOR FLASHES (10 Hz)/GAUGE IN RED
ACTION LAMP FLASHES (1 Hz)
LEVEL 3 : ALERT INDICATOR FLASHES (10 Hz)/GAUGE IN RED
ACTION LAMP FLASHES (1 Hz)
ACTION ALARM SOUNDS
777D Off Highway Truck
CHAPTER : CAT MONITORING SYSTEM
OPERATOR MODES
INPUTS
- ENGINE SPEED / TIMING SENSOR
- ALTERNATOR "R" TERMINAL
SERVICE SERV - ENGINE OIL PRESSURE
METER CODE
MODE 41.4 (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
ODOMETER - TOS
MODE 170
DIGITAL RPM
TACHOMETER - ENGINE SPEED / TIMING SENSOR
MODE 700
RESETTABLE - BODY UP SWITCH
LOAD COUNTER (AFTER 10 SECOND ACTIVATION)
MODE L 74
DIAGNOSTIC SERV SERV
SCROLLING CODE CODE
MODE 030 271 F05
MID CID, FMI
Page: XI-13
Page:
SERVICE MODES
XI-14
HARNESS CODE FOR 769D - 777D OHTs
SERV
HARNESS CODE
CODE -1- 34 USE "S" SERVICE SWITCH TO SCROLL GAUGES
C C kPa
NUMERIC 75
READOUT -2- 170 190 715
GA - 1 GA - 2 GA - 3 GA - 4
SERV SERV - USE "S" SERVICE
CODE CODE
SWITCH TO SCROLL
SERVICE -3- --- 271 F05
CHAPTER : CAT MONITORING SYSTEM
030 FAULTS
MID CID FMI - USE "C" SERVICE
777D Off Highway Truck
SWITCH TO CLEAR
FAULTS
- ALL GAUGES AND INDICATORS
LOG -4- tatle SHOW WORST RECORDED CONDITIONS
MILES KM - USE "C"SERVICE SWITCH
UNITS -5- US SI TO CHANGE UNITS
PERMAMENT
LOAD L 1057
COUNT -6-
ECONOMY - USE "S" SERVICE
SWITCH TO TURN
SHIFT -7- - ON OFF OFF
(NOT 777D)
- USE "C" SERVICE
SWITCH TO TURN
ON
777D Off Highway Truck
CHAPTER : CAT MONITORING SYSTEM
MODULE IDENTIFICATION CODES
MID ELECTRONIC CONTROL
030 Caterpillar Monitoring System (CAT MS)
036 Advanced Diesel Engine Management (ADEM)
027 Electronic Programmable Transmission Control (EPTC II)
083 Automatic Retarder Control (ARC)
CID FMI DESCRIPTION
096 F03 Fuel LevelSender or Circuit Open or Shorted to Bat +
177 F04 Torque Converter Temperature Sensor Shorted to Ground (Bat -)
177 F08 Torque Converter Temperature Signal is incorrect
248 F02 CAT Data Link Communication Abnormal
263 F03 8 V Sensor Power Supply Shorted to BAt +
263 F04 8 V Sensor Power Supply Shorted to ground (Batt -)
271 F03 Action Alarm or circuit shorted to Bat +
271 F05 Action Alarm open Circuit
271 F06 Action Alarm or circuit shorted to ground (Bat -)
324 F03 Action Lamp or Circuit Shorted to Bat +
324 F05 Action Lamp Open Circuit
324 F06 Action Lamp or Circuit shorted to Ground
601 F08 Brake AIr pressure Sensor signal Incorrect
819 F02 Display Data Link Error
821 F03 9V Display Supply Shorted to Bat +
821 F04 9V Display Supply Shorted to Ground (Batt-)
830 F08 Brake Oil Temperature Sensor Signal Incorrect
Page: XI-15
