Electronic Systems of

the Machine
GENERAL OBJECTIVE

Prep arar e instruir al Té cniwithde

opera cI n y Mantenim ie nto de
Caterpillar equipment for what
interpret and solve the
electrical and electronic problems
associated with diagnostic codes.
Syllabus
INTRODUCTION.
MODULE I:
Electronic signals
Alternating Current
Ways to modulate the signal.
Input devices or sources
Switches or switch
Diagnosis in switch-type inputs (reference voltage)
Sender or Senders
Sensors
MODULE II:
Output devices
Solenoids and proportional valves.
Relay
Warning Indicators
MODULE III:
Diagnosis Codes 31
Definition of diagnostic codes

MODULE IV:
Description of the types of ECM
Communication
Hardware and Software
The Personality Module
Internal Structure of an ECM
Registered Events.
MODULE I
 MODULE OBJECTIVES

At the end of this module, the participants

they will be trained to establish the
difference between the different devices of
entry, classify them and explain their
operation, as well as performing the
necessary measurements to diagnose the
state in which they find themselves.
ELECTRONIC SIGNALS
Electronic circuits process a signal
In some way. The signal can be so simple
like the electric pulse created by the closure of
the contacts of a switch, or complex as
a digital signal that evaluates the level of a
fluid.
Signs can be divided into two main categories
groups:
Direct current (DC or DC).
Alternating current (AC)
 FIXED POSITIVE FIXED NEGATIVE

SIGNS
DC
POSITIVE VARIABLE Positive Pulses
 WAYS TO MODULATE THE SIGNAL

Analog Modulation, which represents the parameter as

Voltage level.

Frequency modulation, which represents the parameter

like a frequency level.

Pulse Width Modulation (PWM), which corresponds to

a digital signal that represents the parameter as
duty cycle percentage.
ANALOG SIGNALS

PRESSURE
 DIGITAL SIGNALS
HIGH

TWO LEVELS
DIFFERENT FROM
AMPLITUDE
UNDER
Pulse Width Modulation
WORK CYCLE
TIME ON V/S TIME OFF

A PERIOD
 PERIOD

ONDA
SINUSOIDAL
DEVICES
DE
ENTRY
Input devices are used for the
monitoring of the information associated with the
machine systems. The devices of
entry converts physical parameters such as
speed, temperature, pressure, position, flow or
level in an electronic signal.
Electronic control systems use this
electronic signal (input information) for
the monitoring of the components and to originate
appropriate exit signs.
CLASSIFICATION
SWITCHES.

SENDER.

SENSORS.
SWITCHES
O
SWITCHES
 Switches

Switches have multiple applications.

for control, such as level, flow or
pressure.
The switches have two inside them
contacts, which can normally be
open or closed, depending on the
mechanical construction and the need for
each case.
 TEMPERATURE SWITCH
BRAKE FLUID

MULTITESTER MIDE:
SW REAR BRAKE OIL TEMPERATURE

VOLTAGE.
RESISTANCE (OHMS)
OIL PRESSURE SWITCH
OF BRAKE

MULTITESTER MIDE:
SW PRESSURE BRAKE OIL CIRCUIT

Voltage.

RESISTANCE (OHMS)
 SWITCH LEVEL
ENGINE COOLANT
VARIABLE RESISTANCE WITH SWITCH

SW. REFRIGERANT LEVEL CIRCUIT MULTITESTER MIDE:

VOLTAGE.

RESISTANCE (OHMS)
 FLOW SWITCH
LEVER WITH SWITCH

MULTITESTER MIDE:
SW. OF FLOW REFRIGERANT CIRCUIT

Voltage.
•RESISTENCIA (OHMS)
SWITCH OPERATED BY THE OPERATOR
DIAGNOSIS IN SWITCH TYPE ENTRANCES
To diagnose, locate, and effectively solve problems in
the switches and the inputs of the switches are important
understand the principles of operation.
SENDER OR EMITTERS

0 to 240 Ohms.
70 to 800 Ohms
 TEMPERATURE SENSOR
PASSIVE
VARIABLE RESISTOR.
2 WIRE SENSOR

TEMPERATURE SENSOR CIRCUIT

REFRIGERANT
MULTITESTER MIDE:

VOLTAGE.

•RESISTENCIA (OHMS)
 LEVEL SENSOR
RESISTIVE FUEL
(SENDER)

MULTIMETER MIDE:
FUEL LEVEL SENSOR CIRCUIT

Voltage.

•RESISTENCIA (OHM)

0 to 240 Ohms
70 A 800 ohms They have a resistance
thermistor call, which
They can be of coefficient
positive or negative

The ECM or processor of the

monitor system calculates the
resistance and the system
monitor shows the output in
a meter or indicator of
alert.
SENSORS
Sensors, unlike switches, can
indicate different states of the measured or detected parameter,
for example, a coolant temperature switch for the engine,
it will be activated or deactivated according to the levels
pre-established, that is, in only two situations, by the
contrary a a sensor designed for the same purpose may deliver
different values, depending on the temperature reached.
The sensors to perform this task have inside them
electronic circuits that process information and the
they convert into a signal before it is sent to any
monitoring or electronic control device.
The electronic signal is modulated in three ways:
As frequency. (Hz)
As pulse duration modulation (%)
As analog modulation (Voltage)
SENSORS ARE DIVIDED INTO TWO TYPES

PASSIVE: Sensors that do not process information

before being sent, they do not require food
external and generally have only two terminals.

ACTIVE: sensors that require a voltage of

power supply to operate, they have three terminals, two
of these are used to feed it, and from the third it
obtains the signal or voltage level corresponding to
detected or measured parameter.
Types of sensors
FREQUENCY
PWM
ANALOG
DIGITAL ANALOG (PWM)
FREQUENCY SENSORS

The two most common sensors are:

Magnetic frequency sensor or magnetic pick-up.
Hall effect sensor.

The type of sensor used is determined by engineering.

In a system where the issues are not critical
low speeds, a detector is used
magnetic. In a system where the measurement
low speeds is crucial, it is used a
Hall effect sensor
MAGNETIC SENSOR OR MAGNETIC PICKUP
Frequency sensors of
passive magnetic detection
they convert mechanical movement
in AC voltage.
The voltage and the frequency are
proportional to the speed.

Exit speed of the

transmission in a 797 truck
ELECTRONIC FREQUENCY SENSORS
THE DIGITAL
The behavior of these sensors is similar to that of a Pick Up.
magnetic, the difference lies in that these sensors process the signal
before sending it to a monitoring or control device.
The power supply for this sensor is provided by the device.
associated and the voltage values used are 10, 12.5 or 13 VDC.
HALL EFFECT SENSOR: When an electric current flows through a metal plate
electric current and it is located in a magnetic field
perpendicular to the direction of the current, a develops on the plate
transverse electric field, thereby creating a difference of
potential, which can be measured. When a ferromagnetic object
approaches the Hall effect sensor, the field caused by the magnet
the element weakens. This allows determining the proximity
of an object, as long as it is ferromagnetic.
Measures speed from 0 RPM within a wide temperature range.
ACTIVE SPEED SENSOR

3 WIRE SENSOR.
HALL EFFECT

SPEED SENSOR CIRCUIT

MULTIMETER MIDE:

VOLTAGE.

PULSE WIDTH MODULATION (PWM)

FREQUENCY.
Voltage.
PERCENTAGE.
Note: The ECM in these
sensors DO not contemplate
the Pull UP concept or
reference voltage
Measurements on a frequency sensor
ELECTRONIC

Measurements taken from an electronic frequency sensor, whose

application corresponds to a speed and synchronization sensor
in an electronic fuel injection engine.

The voltage measured between A and B must be between 12 and 13 VDC.

The voltage measured between connector C and B with the key of

When the ignition is ON and the engine is stopped, it must be less than 3 VDC.
or greater than 10 VDC.

During the startup, the voltage measured between terminals C and B

must be between 2 VDC and 4 VDC.
DIGITAL TEMPERATURE SENSOR

It has an oscillator that provides the carrier frequency of the signal.

Depending on the application, that will be the frequency.
500Hz for the exhaust temperature sensors and position of the
accelerator.
5000Hz for temperature and position sensors in general.

A thermistor that varies its resistance with temperature changes.

received and transformed into a PWM digital signal.
POSITION SENSOR

3 WIRE SENSOR.
PWM
VARIABLE RESISTANCE.

THROTTLE POSITION SENSOR CIRCUIT

POSITION SENSOR

4 WIRE SENSOR.

PWM.
HALL EFFECT.

GEAR SHIFT LEVER POSITION SENSOR CIRCUIT

AUTOMATIC
TEMPERATURE SENSOR
DIGITAL
3-WIRE SENSOR.
PWM

OIL TEMPERATURE SENSOR CIRCUIT MULTITESTER MIDE:

TRANSMISSION (ONLY 725/730/735)

PULSE WIDTH MODULATION (PWM)

FREQUENCY.
VOLTAGE.
PERCENTAGE.
 MEASUREMENTS OF A DIGITAL SENSOR
PWM temperature sensor.

The digital multimeter can measure VDC. With the sensor connected to the ECM and the
ignition key in the 'ON' position.

ClavijaAa ClavijaB Supply voltage (8 Vcc)

ClavijaCa ClavijaB Variable voltage according to the measured parameter.

ClavijaCa ClavijaB Frequency (Hz) Constant (depends on type of

sensor

ClavijaCa ClavijaB 5% to 95% (never less than 5% and never 100%)

TEMPERATURE SENSOR AND
ANALOG PRESSURE

3-WIRE SENSOR.
VARIABLE RESISTANCE.

OIL PRESSURE SENSOR CIRCUIT

MULTITESTER MIDE:

VOLTAGE.
 ANALOG TEMPERATURE SENSOR

MEASUREMENTS ON AN ANALOG SENSOR

Sensor connected to the ECM and the ignition key switch in 'ON'.

TerminalA plugBRegulated power supply of 5 VDC from the control.

Terminal Ca connector B0.2 to 4.8 VDC proportional to the measured temperature value.
 ANALOG DIGITAL SENSORS
A sensor with the combination
of two types of sensors, it
use a device that
transform or convert one
voltage level signal, which
it comes from an analog sensor,
to a digital signal.
Examples of these sensors
These sensors today
level sensor of
are being widely
combustible, sensors of
replaced by a format
air pressure in some the PWM sensor much more
Caterpillar equipment, such as compact and durable, what
construction trucks 785B 789B guarantees a life of service
793B/C 797 etc. longer.
LEVEL SENSOR OF
COMBUSTIBLE
ULTRASONIC
SENSOR WITH 4 CABLES.

MULTITESTER MIDE:
FUEL LEVEL SENSOR CIRCUIT

VOLTAGE.

FREQUENCY.

PULSE WIDTH MODULATION (PWM)

 PULL UP

TEST VOLTAGE
TEST VOLTAGE
PULL-UP
IF MEASURED BETWEEN PIN "B" (GROUND) AND "C"
(SIGNAL), WITH THE SENSOR CONNECTED, IT
GET THE VALUE OF THE SIGNAL.

IF MEasured BETWEEN PIN “B” (GROUND) AND “C”

(SIGNAL), WITH THE SENSOR DISCONNECTED,
THE PULL-UP VOLTAGE IS OBTAINED.
 6.5 VCC PULL-UP VOLTAGE

TOWARDS DEVICES OF
ENTRY SENSOR CIRCUIT
OF SIGNALS
 (PULL-UP VOLTAGE)

INPUT DEVICES SENSOR CIRCUIT

Input device OF SIGNALS
 VOLTAGE SUPPLY FOR SENSORS
THE ECMs RECEIVE NOMINAL POWER FROM THE 24 VDC BATTERIES. WITHOUT
THE SUPPLY RANGE VARIES BETWEEN +9 volts and +40 volts.
THE ECM ARE THE ONES RESPONSIBLE FOR GENERATING THE FEEDING TOWARDS
THE SENSORS, BOTH INPUT AND OUTPUT.

Analog sensors: + 5 VDC. +/- 0.5 VDC

DIGITAL SENSORS AND PWM + 8 VDC. +/- 0.5 VDC

FREQUENCY SENSORS + 12.5 VDC. +/- 1 VDC

SUPPLY VOLTAGE
FOR SOLENOIDS OF
FUEL INJECTION. + 105 VDC. +/- 0.5 VDC
 Input Devices
PARAMETER SENSOR ACTIVE OR PASSIVE MEASURE WITH
MONITORED MULTITESTER

PICKUP PASSIVE (2 WIRES) VOLTS/FREQUENCY/OHMS

SPEED
HALL EFFECT ACTIVE (3 CABLES) VOLTS/FREC/PWM
PASSIVE VARIABLE RESISTOR (2 WIRES) VOLTS/OHMS
TEMPERATURE
ACTIVE VARIABLE RESISTOR (3 WIRES) VOLTS/OHMS
ACTIVE VARIABLE RESISTOR (3 WIRES) VOLTS/FREQ/PWM
DRAKE OF ACTIVE (3 CABLES) VOLTS
DEFORMATION
PRESSURE
Quartz crystal ACTIVE (3 CABLES) VOLTS/FREQ/PWM

ACTIVE VARIABLE RESISTOR (3 WIRES)

POSITION HALL EFFECT ACTIVE (3 CABLES) VOLTS/FREQ/PWM

ACTIVE MAGNETORESISTIVE (3 WIRES)

LEVEL OF PASSIVE VARIABLE RESISTOR (2 WIRES) VOLTS/OHMS
Combustible
ACTIVE ULTRASONIC (4 WIRES) VOLTS/FREC/PWM
 PARAMETER SENSOR IS USED IN
MONITORED

PICKUP RPM MOTOR

SPEED
HALL EFFECT COS (CONVERTER) TOS (BROADCAST)

SPEED SYNCHRONISM MOTOR

VARIABLE RESISTOR Refrigerant Temperature Correct

TEMPERATURE
VARIABLE RESISTOR T° AFTER COOLER (AIR
COOLED AFTER THE TURBO

VARIABLE RESISTOR T° ESCAPE

GALGA OF Atmospheric Pressure

PRESSURE DEFORMATION WITH

P° DIRECCIÓN, P° LUBRICACIÓN
VARIABLE RESISTOR
VARIABLE RESISTOR ACCELERATOR
POSITION HALL EFFECT SHIFT LEVER, LIFT
MAGNETORESISTIVE STEERING CYLINDER MOTORCYCLES M
LEVEL OF VARIABLE RESISTOR
FLAMMABLE
ULTRASONIC
MODULE II
OUTPUT DEVICES

SOLENOIDS (ON-OFF, PROPORTIONAL AND PWM)

RELAYS.
LAMPS (INDICATORS).
ALARMS.
DIGITAL DISPLAYS.
ENGINES.
SOLENOIDS
PWM SOLENOID
ELECTRONIC INJECTOR
UNITARY (EUI)
 RELAY OF
MATCH

SOLENOID
DEPARTURE

SWITCH OF
GAME
KEY
CONTACT

BATTERY
 CENTRAL MESSAGE MODULE

INDICATION
INDICATOR STATE OF
ALERT COMUNICACIÓN

AREA
METER CAUTION
UNIVERSAL DEL
INDICATOR

AREA OF
MENSAJE
 MODULE III
DIAGNOSTIC CODES.

DEFINITION OF DIAGNOSTIC CODES.

 DIAGNOSTIC CODES
The diagnosis codes represent a problem with the system of
ELECTRONIC OR ELECTRIC control that needs to be investigated and
correct as soon as possible.
When a diagnosis code is generated, a module of
visualization like the Caterpillar Monitoring System (CMS) allows for alerts
to the operator or to the service technician of the anomalous condition.
The diagnostic codes consist of three codes (MID, CID, and FMI).

The MID (Module Identifier) indicates the electronic module that

generated the diagnostic code.

The CID (Component Identifier) indicates the component in the

system.

The IMF (Failure Mode Identifier) indicates the mode of

present fault.
Note: All electronic control modules
(ECM) that use the data link have a
module identifier (MID). The MID is indicated for
each module:
Engine ECM (front) ... 033
Engine ECM (rear) ... 034
Engine ECM (master) ... 036
Main module of the VIMS ... 049
Transmission ECM ... 081
Chassis ECM ... 087
Brake/cooling ECM ... 116
MODULE IV
ECM
 ADEM I is used in the engines of the 3500 family and practically
it is no longer manufactured, only as a spare part for the units that are in circulation
world.

ADEM II is used in various families of engines whose

the most common applications are Mining, Marine, Generation, Vehicle and
Industrial. Family 3500B, 3400E (HEUI), 3176B (MEUI), 3406E (MEUI)

ADEM III Only on engines whose application is vehicular.

Family 3100 (HEUI), C9 (HEUI), C10, 12, 15 (MEUI)

MAC: (ECM) MULTI-APPLICATION CONTROL.

CONTROL ANALYSIS OF ROLLING OR PATH (RAC).
CHASSIS.
VIMS.
TRANSMISSION
BRAKE-COOLING.
ELECTRICAL CHARACTERISTICS AND COMMUNICATION

Regardless of the type, a

ECM has some
basic characteristics that
allows its operation.
Input signals.
Exit signs.
Power supply for
the sensors that are
they connect
Energy supply from
external batteries for your
functioning.
Different types of
communication, according to the
application.
Observation:
In the ECM used in mining equipment, use
industrial and generation, the modeATA DATA LINK,
It is only used to program the ECMs through
a program called Flash, which is part of the ET.
It is worth noting that this mode of communication in
The 797 truck is only used by the master ECM.
the other ECMs, to make diagnoses and for
to program, CAT DATA LINK is used.
Vital Information Management System (VIMS)

MODULE
MODULE INTERFACE CAT DATA LINK
INTERFACE VIMS ADAM
VIMS

CAT DATA LINK

SENSORS SENSORS

SENSORS

CONTROL OF CONTROL OF
IMPLEMENTS TRANSMISSION
KEYBOARD AND MESSAGE CENTER
 ELECTRONIC SYSTEM 797B MONITORING
METERS.
MONITORING.
ALARMS.
MEASURES.
MEASURES.
CLOCK SYNCHRONIZATION.
MACHINE IDENTIFICATION.
ADEM II ADEM II AUTO LUBRICATION.
MASTER SLAVE 1 MOTOR
MASTER SLAVES
EMISSION CONTROL.
ACCELERATOR POSITION.
FUEL INJECTION.
ALTERNATIVE
ADAM II ACCELERATOR. MACHINE DOWNTIME.
SLAVE 2 ETHER INJECTION.
MOTOR SPEED.
MANUAL PARTIDAL HELP. DIAGNOSTICS.
PRE LUBRICATION. MOTOR SPEED.

TRANSMISSION
ELECTRONIC CLUTCH PRESSURE CONTROL. ECPC
CHASSIS
GEAR FAILURE PROTECTION.
NEUTRAL MATCH. Protection Part INHIBITION IN NEUTRAL GEAR.
•REVERSE ALARM. - LIFT CONTROL. ACCELERATOR POSITION CONTROL.
LOAD COUNTER.–NEUTRALIZE REVERSE. DIRECTOR ADMINISTRATOR TORQUE LIMITER.
•OVERSPEED PROTECTION. - SPEED LIMITER.
BRAKE COOLING
UPPER GEAR LIMIT.
Car Delay Control.
PARKING BRAKE WHEEL MONITOR
CONTROL MOTOR FAN SPEED.
CONTROL SPEED. BRAKE COOLING PUMP.
BRAKE TEMPERATURE MONITORING. CONTROL AND ANALYSIS OF ROADS
Control pressure and cooling rear axle.
 5

4
Transmission ECM.
Chassis ECM.
Brake/cooling ECM.
ECM of the VIMS.
ECM of the RAC (rolling resistance control analysis)
1.-TEACHER 2.- FRONT. 3.- POSTERIOR