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
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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
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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
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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 %.
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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
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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
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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)
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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
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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
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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