Fallas CAT PDV-103
Fallas CAT PDV-103
Shutdown SIS
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Troubleshooting
3500B and 3500C Generator Set and Industrial Engines
Media Number -RENR9364-03 Publication Date -01/10/2009 Date Updated -22/10/2009
i02438066
Speed Control
SMCS - 1901-038
Use this procedure in order to troubleshoot the electrical system if a problem is suspected with the
throttle position signal. Use this procedure if the diagnostic code in Table 1 is active or easily
repeated.
Table 1
Diagnostic Codes Table
System
Description Conditions which Generate this Code
Response
91-8 Throttle Position The Electronic Control Module (ECM) detects an The code is
signal abnormal abnormal throttle signal for five seconds. logged.
The speed control provides a throttle signal and a droop signal to the engine's ECM. The output
for rated speed is a pulse width modulated signal (PWM) at a constant frequency. The speed
signal varies with the position of the speed adjust potentiometer. The output for droop is a PWM
signal at a constant frequency. The droop signal varies with the position of the droop adjust
potentiometer. The output signal is referred to as a duty cycle or as a PWM signal. The output
signal is expressed as a percentage between 0 and 100 percent for the speed adjust and a
percentage between 0 and 10 percent for the droop adjust.
The ECM calculates the desired engine rpm from the rated speed signal and the droop signal. The
rated speed signal is valid when the duty cycle is in the range of 5 to 95 percent. If the ECM
determines that the rated speed signal is invalid, the engine rpm will be set to the programmed low
idle.
The droop signal is valid when the duty cycle is in the range of 15 to 85 percent. If the ECM
determines that the droop signal is invalid, the engine will run with no droop which is referred to
as isochronous mode.
Some applications may choose not to use the speed control. Some applications may use a load
sharing module. The load sharing module is configured to provide the engine control with a rated
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speed signal. The signal has the same characteristics as the above defined signal. Some of these
load sharing modules can not provide a signal until the engine is running. In these cases,
troubleshooting should be performed while the engine is running.
Illustration 1 g01218219
Typical schematic
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Illustration 2 g01218220
P1 ECM connector
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Illustration 3 g01218221
P2 ECM connector
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Illustration 4 g01218222
"Connector "A""
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Illustration 5 g01234146
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Illustration 6 g01218225
Customer connector
B. Thoroughly inspect the ECM connectors. Inspect all of the other connectors for the circuit.
Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.
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C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are
associated with the circuit.
D. Check the ECM connector (allen head screw) for the proper torque. Refer to
Troubleshooting, "Inspecting Electrical Connectors" for details.
E. Check the harness and the wiring for abrasion and for pinch points.
Expected Result:
All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring
are free of corrosion, of abrasion, and of pinch points.
Results:
Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure
that all of the seals are properly in place and ensure that the connectors are completely
coupled.Verify that the repair eliminates the problem.
STOP
C. Connect one probe of a voltmeter to the +Battery terminal of the speed control. Connect one
probe of the voltmeter to the −Battery terminal of the speed control.
Expected Result:
Results:
• OK - The voltage is 24 ± 3 VDC. The voltage supply to the speed control is correct.
Proceed to Test Step 3.
Repair: Check wire 998-BR for continuity to the ECM connector P1-5. Check wire 104-RD
for continuity to the breaker for the "relay breaker". Check the "relay breaker" and the
"battery breaker" in order to ensure that the breakers are not tripped.
STOP
A. Determine if the problem is with the input for the throttle or the droop.
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C. Observe the position of the throttle on Caterpillar Electronic Technician (ET) as you turn
the speed adjust potentiometer.
D. Observe the droop on Cat ET as you turn the droop adjust potentiometer.
Expected Result:
The throttle position on Cat ET varies with the turning of the speed adjust potentiometer. The
droop on Cat ET varies with the turning of the droop adjust potentiometer.
Results:
• RATED SPEED - The throttle position on Cat ET does not vary with the turning of the
speed adjust potentiometer. Proceed to Test Step 4.
• DROOP SPEED - The droop on Cat ET does not vary with the turning of the droop adjust
potentiometer. Proceed to Test Step 5.
D. Start at the low idle position. Slowly turn the speed adjust potentiometer in the other
direction. Monitor the position of the throttle on Cat ET.
Expected Result:
The throttle position on Cat ET reads 0 percent at the lowest setting and 0 to 100 percent as the
speed adjust potentiometer is adjusted.
Results:
Repair: The problem may be intermittent. If the problem is intermittent, perform the
diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".
STOP
• Not OK - The throttle position on Cat ET does not vary as the speed adjust potentiometer is
adjusted. Proceed to Test Step 6.
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D. Slowly turn the droop adjust potentiometer in a clockwise direction. Monitor the droop on
Cat ET.
Note: Do not overturn the droop adjust potentiometer in the clockwise direction. The signal
will become erratic.
Expected Result:
The droop on Cat ET reads 0 percent at the lowest setting and 0 to 10 percent as the droop adjust
potentiometer is adjusted.
Results:
Repair: The problem may be intermittent. If the problem is intermittent, perform the
diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".
STOP
• Not OK - The droop on Cat ET does not vary as the droop adjust potentiometer is adjusted.
Proceed to Test Step 7.
B. Set the multimeter to "VDC". Press the "Hz" button twice so that the % symbol is displayed.
C. Place one probe of the multimeter on the S terminal of the speed control. Place the other
probe on the −Battery terminal of the speed control.
D. Monitor the output of the percent duty cycle from the speed control on the multimeter. Turn
the speed adjust potentiometer from the low setting to the high setting.
Note: The throttle position on Cat ET will not match the percent duty cycle on the
multimeter.
Expected Result:
The duty cycle is between 4 and 10 percent at the low setting and between 90 and 95 percent at the
high setting.
Results:
• OK - The speed control is supplying the correct duty cycle. Proceed to Test Step 8.
Repair: Temporarily install another speed control. Verify that the problem is no longer
present. Reinstall the old speed control. If the problem returns, replace the speed control.
STOP
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B. Set the multimeter to "VDC". Press the "Hz" button twice so that the % symbol is displayed.
C. Place one probe of the multimeter on the D terminal of the speed control. Place the other
probe on the −Battery terminal of the speed control.
D. Monitor the output of the percent duty cycle from the speed control on the multimeter. Turn
the droop adjust potentiometer from the low setting to the high setting.
Expected Result:
The duty cycle is between 15 and 85 percent. This range should be attainable.
Results:
• OK - The speed control is providing the correct droop signal. Proceed to Test Step 9.
Repair: Temporarily install another speed control. Verify that the problem is no longer
present. Reinstall the old speed control. If the problem returns, replace the speed control.
STOP
B. Set the multimeter to "VDC". Press the "Hz" button twice so that the % symbol is displayed.
C. Measure the voltage between pins P1-10 and P1-5 on the ECM connectors.
D. Monitor the output of the percent duty cycle from the speed control on the multimeter.
Monitor the percent throttle position on Cat ET. Turn the speed adjust potentiometer from
the low setting to the high setting.
Expected Result:
The duty cycle is between 4 and 10 percent at the low setting and between 90 and 95 percent at the
high setting. The percent throttle position is between 0 and 100 percent for the above settings of
the speed adjust potentiometer.
Results:
Repair: There is a problem in the wiring between P1-10 and the S terminal of the speed
control. Verify that the low idle switch is functioning properly.
STOP
• Not OK - Throttle Position - The duty cycle is correct but the throttle position is not
correct. The ECM is not processing the correct signal.
Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing
the ECM".
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STOP
B. Measure the voltage between pins P2-69 and P1-5 on the ECM connector.
C. Set the multimeter to "VDC". Press the "Hz" button twice so that the % symbol is displayed.
D. Monitor the output of the percent duty cycle of the droop signal at the speed control with the
multimeter. Monitor the droop on Cat ET. Turn the droop adjust potentiometer from the low
setting to the high setting.
Note: Do not overturn the droop adjust potentiometer in the clockwise direction. The signal
will become erratic.
Expected Result:
The duty cycle is between 1 and 15 percent at the clockwise setting and between 85 and 99
percent at the counterclockwise setting. The droop is between 0 and 10 percent for the above
settings of the droop adjust potentiometer.
Results:
Repair:
STOP
Repair: There is a problem in the wiring between P2-69 and the D terminal of the speed
control.
STOP
• Not OK - Droop - The duty cycle is correct but the droop is not correct. The ECM is not
processing the correct signal.
Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing
the ECM".
STOP
Copyright 1993 - 2013 Caterpillar Inc. Tue Dec 17 15:43:59 UTC-0400 2013
All Rights Reserved.
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