Electronic Control (Power Train System) (UENR4109-02)

SMCS - 1400, 4000, 7610 i05841290

Electronic Control Modules PSP

Machine ECM 202 -000A
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Illustration 1 g03307257
Illustration 2 g01309473
ECM Connectors and Contacts
The Machine ECM determines actions that are based on input information and memory
information. After the Machine ECM receives the input information, the ECM sends a
corresponding response to the outputs. The inputs and outputs of the Machine ECM are
connected to the machine harness by two 70 contact connectors (J1 and J2). The ECM sends
the information to the Caterpillar Electronic Technician (Cat ET) on the Cat Data Link.

Note: The ECM is not serviceable. The ECM must be replaced if the ECM is damaged. Replace
the ECM if a failure is diagnosed.

ECM Pull Up Voltage

In order to aid in diagnostics of certain types of electrical circuits that are controlled by the ECM,
an internal "pull up voltage" is connected to ECM switch and sensor signal input contacts. An
above normal voltage is internally connected to the ECM signal input circuit through a resister.

During normal operation, the switch or sensor signal will hold the circuit low or at a certain signal
amplitude, however, circuit conditions such as a loss of power to the component, a
disconnection, or an open circuit will allow the circuit to be pulled high by the ECM pull up
voltage. This condition will result in an above normal voltage condition at the ECM contact. As a
result, the ECM will activate an FMI 03 (voltage above normal) diagnostic code for the affected
circuit.

The types of ECM input circuits that have pull up voltage present are:

Pulse Width Modulated (PWM) sensor input circuits

Switch to Ground Input switch input circuits

Active analog (voltage) input signal circuits

Passive analog (resistance) input signal circuits

ECM Pull Down Voltage

In order to aid in diagnostics of electrical circuits that are controlled by the ECM, an internal "pull
down voltage" is connected to ECM switch to battery type input circuits.

During normal operation, the switch contacts that are allowing the connection to a voltage source
will hold the circuit high. When circuit conditions such as a loss of power to the switch supply
voltage, a disconnection in the switch circuit or an open circuit will allow the circuit to be pulled
low by the ECM pull down voltage. This condition will result in a below normal voltage condition
at the ECM contact. As a result, the ECM will activate an FMI 04 (voltage below normal)
diagnostic code for the affected circuit.

Pin Locations
Table 1

Machine ECM Contact Description J1 Contact Descriptions(1)

No.(2) Type Function

 2 Differential Speed Input + Transmission Output Speed Sensor 1 +
3 Differential Speed Input - Transmission Output Speed Sensor 1 -
4 Differential Speed Input + Transmission Output Speed Sensor 2 +
5 Differential Speed Input - Transmission Output Speed Sensor 2 -
10 Cat Data Link + Cat Data Link +
13 Battery Return Battery -
15 Differential Speed Input + Torque Converter Output Speed Sensor +
16 Differential Speed Input - Torque Converter Output Speed Sensor -
20 Cat Data Link - Cat Data Link -
22 Analog Input Torque Converter Oil Temperature Sensor
23 Battery Return Battery -
29 Analog Input Transmission Oil Temperature Sensor
31 Battery Power Input Battery +
33 Switch to Ground Input Reverse Switch (N/O)
34 Switch to Ground Input Reverse Switch (N/C)
35 Switch to Ground Input Parking Brake Switch Engaged
38 Battery Power Input Battery +
39 Battery Power Input Battery +
40 Switch to Ground Input Parking Brake Switch Released
44 Sensor Power Output 8V Supply
45 Sensor Power Return 8V Return
47 Battery Power Input Battery +
48 Sourcing Driver Output Transmission Speed Clutch 1
49 Sourcing Driver Output Transmission Speed Clutch 2
50 Sourcing Driver Return PWM Return 1-4
51 Sourcing Driver Output Transmission Speed Clutch 3
52 Sourcing Driver Output Brake Proportional Solenoid
56 Sensor Power Return 10V Return
57 Battery Return Battery -
64 Switch to Ground Input Powertrain Filter Bypass Switch
65 Switch to Ground Input Transmission Reverse Clutch
66 Sourcing Driver Output Transmission Forward Clutch
69 Sensor Power Output 10V Supply
70 Battery Return Battery -
(1) Contacts that are not listed are not used.
(2) The connector contacts that are not listed are not used.
Table 2

Machine ECM Contact Description J2(1)

No.(2) Type Function

3 Sourcing Driver Output Parking Brake Dump Valve Solenoid
4 Sourcing Driver Return Park Brake Return
15 PWM Input Decel Pedal Signal
22 Return Sensor / Driver Return
28 Switch to Ground Input Upshift Switch (N/O)
29 Switch to Ground Input Upshift Switch (N/C)
30 Switch to Ground Input Downshift Switch (N/O)
31 Switch to Ground Input Downshift Switch (N/C)
32 PWM Input Service Brake Position Sensor
33 PWM Input Direction Lever Position Sensor (FNR)
36 Switch to Ground Input Forward Switch (N/O)
37 Switch to Ground Input Forward Switch (N/C)
50 PWM Input Engine Throttle Switch
51 PWM Input Bi-Directional Switch
67 CAN Data Link + CAN A Data Link +
68 CAN Data Link - CAN A Data Link -
(1) The ECM responds to an active input only when all of the necessary conditions are satisfied.
(2) The connector contacts that are not listed are not used.

Inputs
The machine has several different types of input devices. The ECM receives machine status
information from the input devices and determines the correct output action that is needed in
order to control machine operations based on memory and software parameters. The machine
utilizes the following types of inputs: switch type and sensor type.

Switches provide signals to the switch inputs of the ECM. The possible outputs of a switch are
listed: an open signal, a grounded signal and + battery signal.

Sensors provide an electrical signal to the ECM that constantly changes. The sensor input to the
ECM can be one of several different types of electrical signals such as: pulse width modulated
(PWM) signals, voltage signals and frequency input signals. Each possible input to the ECM is
listed in the tables for the 70-pin connectors.

Inputs provide information to the ECM in the form of sensors or switches.

Sensors
Sensors provide information to the ECM about the intent of the operator or changing conditions.
The sensor signal changes proportionally to the changing of operator input or changing
conditions. The following types of sensor signals are used by the ECM.

Frequency - The sensor produces a signal and the frequency (Hz) varies as the condition
changes.

Pulse width modulated - The sensor produces a signal. The duty cycle of the signal varies as
the condition changes. The frequency of this signal is constant.

Analog - The ECM measures the voltage that is associated to a specific condition of the control.

Transmission Output Speed Sensor

Illustration 3 g03372196
The ECM receives signals from the transmission output speed sensor as a frequency signal. The
transmission output speed sensor is an active sensor. The signal indicates the rotational speed
of the connection from the output of the torque converter to the input of the transmission. The
signal is generated by a gear passing in front of the sensor, with one full pulse generated per
tooth on the gear. The signal is low when a gear tooth is in front of the sensor and high when in a
valley.

Torque Converter Output Speed Sensor

Illustration 4 g03372298
The ECM receives signals from the torque converter output speed sensor as a frequency signal.
The torque converter output speed sensor is a passive sensor. The signal indicates the rotational
speed of the connection from the output of the torque converter to the input of the transmission.
The signal is generated by a gear passing in front of the sensor, with one full pulse generated
per tooth on the gear. The sensor has an inductive coil that creates a voltage pulse to the ECM
when a gear tooth passes the sensor. The ECM interprets the frequency of the pulses as the
speed of the gear.

Torque Converter Oil Temperature Sensor

Illustration 5 g03372390
The ECM receives signals from the torque converter oil temperature sensor as an analog signal.
The sensor is a passive sensor. The voltage output of the sensor changes proportionally to the
temperature of the torque converter oil.

Transmission Sump Temperature Sensor

Illustration 6 g03372390
The ECM receives signals from the transmission sump oil temperature sensor as an analog
signal. The sensor is a passive sensor. The voltage output of the sensor changes proportionally
to the temperature of the transmission oil.

Deceleration Pedal Sensor

Illustration 7 g03673784
The deceleration pedal position sensor is an active pulse width position sensor. The sensor
sends a pulse width modulated signal to the ECM. The signal allows the ECM to determine the
position of the service brake pedal.

Service Brake Pedal Position Sensor

Illustration 8 g03373852
The service brake pedal position sensor is an active pulse width position sensor. The sensor
sends a pulse width modulated signal to the ECM. The signal allows the ECM to determine the
position of the service brake pedal.

Forward Neutral Reverse Sensor

Illustration 9 g03674106
The forward neutral reverse sensor is an active pulse width position sensor. The sensor sends a
pulse width modulated signal to the ECM. The signal allows the ECM to determine the operator
request for direction of movement.

Engine Speed and Bi-Direction Control

Illustration 10 g03674139
The engine speed and bi-direction control knobs act as multiple position switches. The two
knobs generate specific PWM signals depending on the position of each knob. The ECM uses
the two PWM signals to determine the operator request for engine speed and bi-direction. The
following table shows the PWM signal associated with each position.

Table 3
Engine Speed and Bi-Direction Control Sensor
Engine Speed Control Bi-Direction Control
Duty Duty
Position Position
Cycle Cycle
Speed 1 (Lowest) 10%
Speed 2 23% Off 23%
1st Gear Forward 1st Gear
Speed 3 36% 36%
Reverse
1st Gear Forward 2nd Gear
Speed 4 49% 49%
Reverse
2nd Gear Forward 1st Gear
Speed 5 62% 62%
Reverse
Auto Shift (auto-kickdown, MVP, 2nd Gear Forward 2nd Gear
75% 75%
FER)) Reverse
Speed 6 (Highest) 88%
Switches
Switches provide an open signal, a ground signal, or a +battery signal to the inputs of the ECM.
Switches are open or closed.

When a switch is open, no signal is provided to the corresponding input of the ECM. This
“no signal” condition is also called “floating”.

When a switch is closed, a ground signal or a +battery signal is provided to the

corresponding input of the ECM.

Forward and Reverse Switches

Illustration 11 g03587184
The forward and reverse switches are single pole limit switches. The forward and reverse
switches each have a normally open contact and a normally closed contact. When the switch is
not activated, the normally open contact floats to a high voltage state, and the normally closed
contact is pulled to a low voltage state. When the switch is activated, the normally open contact
is pulled to a low voltage state, and the normally closed contact floats to a high voltage state.
The ECM monitors the state of the two contacts for each switch and determines the operator
request for forward or reverse movement.

Parking Brake
Illustration 12 g03673551
The parking brake switch is a two position switch with a normally open contact and a normally
closed contact. The contacts provide switch to ground inputs to the ECM. Through these
contacts, the ECM can determine if the parking brake is engaged or disengaged. When the
parking brake is activated, the switch prevents the ECM from energizing the brake solenoid,
preventing the brakes from being released.

Transmission Filter Bypass Switch

Illustration 13 g03320660

Upshift and Downshift Switches

Illustration 14 g03588881
The upshift and downshift switches are single pole push-button switches. Each switch has a
normally connected contact and a normally open contact. The ECM monitors the two contacts
and determines the operator request to either upshift or downshift.

Outputs
The ECM responds to decisions by sending electrical signals to the outputs. The outputs can
create an action or the outputs can provide information to the operator or the service technician.

Proportional Solenoids
Transmission Clutch Solenoids

Illustration 15 g03673669
Forward clutch solenoid
Reverse clutch solenoid
First gear clutch solenoid
Second gear clutch solenoid
Third gear clutch solenoid
Each of these solenoid valves is designed to control the flow of to a clutch plate. When the
solenoid is not engaged or receiving a low duty cycle signal, the solenoid does not allow Power
Train hydraulic oil to engage a clutch plate. As the duty cycle of the signal to the solenoid
increases, the solenoid allows some flow and the clutch begins to engage. When the duty cycle
of the signal to the solenoid is at the maximum, the flow of Power Train hydraulic oil fully
engages the clutch. The engagement of a clutch is proportional to the duty cycle of the signal
sent by the ECM.

Note: The solenoid coils are not designed to operate using 24 DCV directly. The ECM sends a
PWM signal of 24 V at a duty cycle that will provide the necessary current to the solenoid coils.
Do NOT activate the coils by using 24 DCV (+battery). The life of the coils will be reduced
drastically. A source of 12 DCV should be used, if the coils must be activated by not using the
ECM.

Brake Solenoid

Illustration 16 g03372925
The brake solenoid is designed to control the flow of brake oil to the brakes. The brakes are
spring applied and hydraulically released. When the solenoid is not engaged or receiving a low
duty cycle signal, the solenoid does not allow brake oil to disengage the brakes. As the duty
cycle of the signal to the solenoid increases, the solenoid allows some flow and the brakes begin
to release. When the duty cycle of the signal to the solenoid is at the maximum, the flow of brake
oil fully releases the brakes. The engagement of the brakes is inversely proportional to the duty
cycle of the signal sent by the ECM.

Note: The solenoid coils are not designed to operate using 24 DCV directly. The ECM sends a
PWM signal of 24 V at a duty cycle that will provide the necessary current to the solenoid coils.
Do NOT activate the coils by using 24 DCV (+battery). The life of the coils will be reduced
drastically. A source of 12 DCV should be used, if the coils must be activated by not using the
ECM.

On/Off Solenoids
Brake Dump Solenoid

Illustration 17 g03373579
The brake dump solenoid is an on/off solenoid valve. The solenoid is activated when the limit
switch on the brake pedal is activated. The solenoid controls if the brake hydraulic oil is being
directed to the tank, or allowed to be distributed by the brake solenoid.

Data Link
Electronic communication between the Machine Control ECM, the Engine ECM and the other
control modules on the machine is conducted over data link circuits. The data link circuits allow
the sharing of information with other electronic control modules. The data link circuits are
bidirectional. The data link circuit allows the ECM to send information and to receive information.

The electronic communication system consists of two types of data link systems.

Cat Data Link

SAE J1939 (CAN) Data Link

The two types of data links are the main structure for communication between all of the control
modules on the machine.

The SAE J1939 Data Link circuit is mostly used for faster operational communication between
the control modules on the machine. The Cat Data Link is used for some of the internal
communication that does not require the faster speeds and is used for communication with
external devices such as the Caterpillar Electronic Technician (Cat ET) service tool.

Cat Data Link

The Cat Data Link is an input/output of the ECM. The data link uses the connector for the service
port in order to communicate with the Caterpillar Electronic Technician. A data link connection is
provided for the product link.

Note: The control for the product link provides a global positioning system for the machine.

The data link is bidirectional. The bidirectional link allows the ECM to input information and
output information. The data link consists of the following parts: internal ECM circuits, the related
harness wiring, the service tool connector and the connector for the product link. The Cat Data
Link connects to the ECM at contact J1-10 (wire 893-GN(Green)) and contact J1-20 (wire 892-
BR(Brown)).

The ECM receives commands from the Cat ET in order to change the operating modes. The
Cat ET will read the service codes that are stored in the memory of the ECM. The Cat ET
will clear the service codes that are stored in the memory of the ECM.

The ECM sends the input and the output information to the Caterpillar ET.

Note: An electronic control module that uses the Cat Data Link will have a module identifier. The
MID for the Machine Electronic Control Module is 039.

CAN Data Link

A data link is required for communication with the service tool (Cat ET) and the electronic control
modules as well as instrument clusters and other devices that use this communications protocol.
The data link is not used in order to broadcast any diagnostic information.

PSP-000AD5AD
2024/05/16
03:09:00+07:00
i05791053
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