CATERPILLAR® Service Information System Tela anterior Bem-vindo: u060erl < produtos: INDUSTRIAL ENGINE Modelo: C-26 INDUSTRIAL ENGINE BFMO2322 Configuraggo: C-16 Industrial Engine BFMO0001-UP Localizacao e Solucdo de Problemas C-10, C-12, C-15 and C-16 Industrial Engines Numero de Midia -SENR9S76-05 Data de Publicagéo -01/09/2005 Data de Atualizacéo -19/09/2005 lora71744 Throttle Position Sensor Circuit - Test SMCS - 1913-038 System Operation Description: The throttle position sensor (TPS) eliminates the mechanical throttle and governor linkages. The TPS utilizes the lever movement by the operator to send an electrical signal to the Electronic Control Module (ECM) for the engine. The signal from the TPS and the signal from the speed/timing sensors are processed by the ECM in order to control the engine speed, The direct fuel control replaces the throttle position sensor when an external governor is used. An electrical converter converts the 0 to 200 mA current from the governor into a pulse width modulated signal that can be used by the ECM. The use of the direct fuel control will disable the governing strategy and speed controlling strategy of the engine software, ‘Test Step 1. Identify the Speed Control System that is Used Determine if a throttle position sensor, direct fuel control, or J1939 throttle is being used to control engine speed. Expected Result: The desired engine speed is controlled with a throttle position sensor, direct fuel control, or J1939 throttle. Results: + Throttle Position Sensor - A throttle position sensor is used to control engine speed. Proceed to Test Step 2. * Direct Fuel Control - Direct fuel control is used to control engine speed. Proceed to Test Step 10, + 51939 Throttle - The 11939 data link is utilized for desired engine speed, Repair: Verify that the "Desired Speed Input Configuration" parameter is programmed to "CAN Input". Also verify that the "Throttle Position Sensor" parameter is programmed to "Not Installed” and verify that the "Direct Fuel Control Mode” parameter is programmed to "Disabled" Refer to Troubleshooting, "CAN Data Link Circuit - Test". hips:sis.cat.com siswebisiswebtechdccschdoc_prnt pagejsp?rturrul=Isiswebisiswebpracucisearcriproductheaderrfotamesetjsp&calledpage=/... 1118STOP Test Step 2. Check Programmable Parameters A. Connect the Caterpillar Electronic Technician (ET) to the data link connector. B, Tum the keyswitch to the ON position, C. Verify that the "Throttle Position Sensor" parameter is programmed to "Installed". Also, verify that the "Direct Fuel Control Mode" parameter is programmed to "Disabled" and verify that the "Desired Speed Input Configuration" parameter is programmed to "PWM". Expected Result: ‘The parameters are programmed correctly. Result + OK - The parameters are programmed correctly. Proceed to Test Step 3 + Not OK - The parameters are not programmed correctly. Repai STOP Test Step 3. Inspect Electrical Conneetors and Wiring ‘ogram the parameters. Verify that the repair eliminates the problem. cow Thretile Position Throttle Position Sensor 1403/P103 Pat/J64 Pit Signal c 10. F702-GN 56 “Battory B apotiery A 15. Braker Note: Refer to Electricol Syelam Schematic tor Wore Information Mustration 1 ‘Schematic for throttle position sensor hips:sis.cat.com sisweblsiswebtechdcctechdoc_ print pagejspreturrt= 200923431 iswebisiswehprosteisearcnproductheadernforamesetisp&calledpage=/... 2118Mlustration 2 200763651 Electronic throttle position sensor Lever —_ on. Ae Mounting Z Surface ae TF B Mlustration 3 1200763656 Lever operated # :le position sensor "Stops" for the leverare set to "Low idle" and "High idle”, hips:sis.cat.com sisweblsiswebtechdcctechdoc_ print pagejspreturrt= iswebsiswehprocteisearcnproductheadernforamesetisp&calledpage=/... 318cf Mounting Miia Surfoce a =n ‘Throttle position sensor with adjustment knob Mlustration 4 200763658 ‘Use a CCW rotation fortwo tums for "High idle" and use CW rotation fortwo tums for "Low idle". Pushing the knob "IN" will also retum the engine to "Low idle’ Table 1 Pin Assignment on the Sensor Connection Pin A Switched positive battery Pin B Negative battery on bus bar Pin Throttle position signal ‘The output of the sensor is a constant frequency signal with a pulse width that varies with the throttle position, The pulse width measures the duty cycle. The Pulse Width Modulated signal (PWM) is expressed as a percentage of the duty cycle. This percentage is between 0 and 100 percent. The TPS will produce a minimum duty cycle when the throttle is released. The TPS will produce a maximum duty cycle when the throttle is fully actuated ismebsiswehprodteisearcnproductheadernforamesetisp&calledpage=/... 418 hips:sis.cat.com sisweblsiswebtechdcctechdoc_ print pagejspreturrt=10% Duty Cycle —— 90% Duty Cycle EC H#—| l— p—+] Mlustration $ 200751431 Duty Cycle hitps:sis.cal.comisisweblsiowebtechdcctechdoe_prnt pagejepeturusl-Isiswebisiwebprecictsearc'iproductheadernforamesetjepcalledpage-/... S18PWM PWM is Pulse Width Modulation I Ul ce % Duty Cycle = a x 100 H = High Portion of Signal P = Period of Signal Mlustration 6 200751478 Definition of PWM. ipsssis cateThrotile Position vs. PWM Input 100% TZ (Programmed High Tdle) Throttle Position % 0% a (Programmed 9 § 10 90 95 100 tow Idle) PWM Input to ECM (% Duty Cycle) 5% “Deadband" ensures engine will reach Low Idle 5% "Deadband" ensures engine will reach High Idle BB Evgine drops to Low Idle and o foul is logged Mustration 7 200766798 Percent of Throttle Position versus PWM Input Table 2 Throttle Position | Duty Cycle | Nominal Duty Cycle Low idle 510% 8% High idle 90-95% 92% PWM Input Requirements ‘The following criteria are required for the correct operations of a throttle p Caterpillar: "Activepull up/pull down with output protection” "Sensor stop" + Low stop 7.5% + 2.5% + High stop 92.5% + 2.5% “Output frequency" + Minimum of 300 Hz. * Nominal of $00 Hz hitps:sis.catcomisisweblsiswebtechdcctechdoe_print pagejep7returusI=Isisweblsiwebiprocktsearch/poductheaderinfoftamesetjspScalledpage"/ me+ Maximum of 700 Hz “High output voltage” + Minimum of 4.5 VDC + Maximum of 32 VDC "Low output voltage" * Minimum of -0.3 VDC * Maximum of 0.5 VDC "Sink current” + -15mA "Source current" + -20mA Note: The sourcing driver must be capable of sinking 1.5 mA if the output voltage of the output driver is less than 13,0 VDC. “Output linearity" * £2.5 % duty cycle versus throttle lever position 413.0. ¥ B41 K Input Output For Check Test t 3900 PF Level Mlustration 8 200762874 ‘Simulated ECM Load A. Tum the keyswitch to the OFF/RESET position. B. Check the connectors and wiring for the following problems: damage, corrosion, abrasion and ips:sis.cat.com siswebisiswebtechdccechdoc_prnt page jsp?rturrrl=Isiswsbisiswebpracucisearchiproductheaderrfoamesetisp&calledpage-/.. 8/18incorrect attachment. Pay close attention to the following areas: © J1/P1 ECM connector © J61/P61 Customer connector © J403/P403 Throttle Position Sensor connector Refer to Troubleshooting, "Electrical Connectors - Inspect" for more information. Expected Result: ‘The connectors and wiring are free of the following problems: damage, corrosion, abrasion and incorrect attachment. Results: * OK - Proceed to Test Step 4, * Not OK- 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.Clear all logged diagnostic codes, STOP ‘Test Step 4. Check the Voltage at the Sensor A. Turn the keyswitch to the ON position. The engine should be OFF. B, Measure the voltage between P403-A and P403-B. Expected Result: The supply voltage should be between 11,0 VDC and 13.5 VDC for a 12 Volt system and the supply voltage should be between 22.0 VDC and 27.0 VDC for a 24 Volt system. Results: * OK- The supply voltage is reaching the sensor. Proceed to Test Step 5. + Not OK - Proceed to Test Step 6. ‘Test Step 5. Check the Throttle Position Sensor Duty Cycle at the Sensor ‘A. Turn the keyswitch to the OFF position. B, Remove the signal wire from Pin C of the throttle position sensor. C. Set the digital multimeter to the VDC. D. Press the Hz button twice in order to activate the display that will show the symbol for percent. E, Place the positive probe of the multimeter on Pin C of the throttle position sensor. F, Place the negative probe of the multimeter on Pin B of the throttle position sensor hips:sis.cat.com sisweblsiswebtechdcctechdoc_ print pagejspreturrt= ismebsiswehprodteisearcnproductheadernforamesetisp&calledpage=/... 918G. Move the throttle from low idle to high idle and monitor the duty cycle output of the throttle position sensor on the multimeter. Expeeted Result: The duty cycle should be between 5.0 percent and 10.0 percent when the throttle is at low idle. The duty cycle should be 90.0 percent to 95.0 percent when the throttle is at high idle. Results: + OK- A valid signal appears at the sensor connector. Proceed to Test Step 7. + Not OK - The duty cycle is out of the range Repair: Perform the following diagnostic procedure Refer to Troubleshooting, "Throttle Position Sensor - Calibrate", STOP ‘Test Step 6. Measure No-Load Battery Voltage ‘A. Measure the no-load battery voltage at the battery posts. Note: Load test the batteries with the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of the 4C-4911 Battery Load Tester " and Special Instruction, SEHS7633, "Battery Test Procedure" for further assistance. Expected Result: The no-load voltage should be at least 11,0 VDC for a 12 Volt system and the no-load voltage should be at least 22.0 VDC for a 24 Volt system, The batteries should also pass the load test Results: + OK - The voltage is in the range at the battery posts. Repair: Measure the voltage at the harness side of the 1403/P403 Throttle Position Sensor. 1. Ifthe voltage is less than 11.0 VDC for a 12 volt system or less than 22.0 VDC for a 24 volt system, there is a problem in the wiring between the battery and the sensor connector. 2. Repair the wiring that is required. 3. Verify that the repair eliminates the problem. 4. Clear all logged diagnostic codes. STOP + Not OK - The voltage is out of the range at the battery posts. Repair: The battery voltage is out of the range. 1. Replace the batteries 2, Repeat the battery test, hips:sis.cat.com siswebisiswebtechdccechdoc_prnt pagejsp?rturrul=Isiswebisiswebpracucisearchiproductheaderrfotamesetisp&calledpage.. 10183. Verify that the problem is eliminated. 4. Clear all logged diagnostic codes. STOP Test Step 7. Check the Duty Cycle of the Throttle Signal at the ECM A. Tum the keyswitch to the OFF position. B. Remove P1-66 throttle position signal wire from the P1 ECM connector. C. Set the 9U-7330 Digital Multimeter to the VDC. D. Press the Hz button twice in order to activate the display that will show the symbol for percent. Place the positive probe of the multimeter on P2-24 of the ECM connector. F, Place the negative probe of the multimeter on P1-5 of the ECM connector. G. Move the throttle from low idle to high idle and monitor the duty cycle output of the throttle position sensor on the multimeter. Expected Result: The duty cycle should be between 5.0 percent and 10.0 percent when the throitle is at low idle. The duty cycle should be 90.0 percent to 95.0 percent when the throttle is at high idle. Resul * OK- The duty cycle is in the range. Proceed to Test Step 9. + Not OK - There is a problem with the signal wire for the throttle position signal in the wiring hamess. Proceed to Test Step 8. ‘Test Step 8. Install Supply Bypass Wire for the Throttle Position Signal Wire A. Tum the keyswitch to the OFF position. & Remove the throttle position signal wire 1403-C from the sensor connector. Install a jumper wire between 1403-C and P1-66 Throttle Position. yo Tum the keyswiteh to the ON. E, Move the throttle from low idle to high idle and monitor the duty cycle output of the throttle position sensor on ET. Expected Result: ‘The duty cycle should be between 5.0 percent and 10.0 percent when the throttle is at low idle. The duty cycle should be 90.0 percent to 95.0 percent when the throttle is at high idle. Results: + OK- The duty cycle is in the range. hips:sis.cat.com siswebisiswebtechdccechdoc_prnt pagejsp?rturrul=Isiswebisiswebpracucisearciproductheaderrfotamesetjsp&calledpage... 11/18,Repai The wiring between the ECM and the sensor is bad. 1. Permanently replace the wiring, 2. Verify that the repair eliminated the problem. 3. Clear all logged diagnostic codes. STOP + Not OK - The duty cycle is out of the range. Repair: Perform the following diagnostic procedure. Ensure that the connectors and the wiring are free of damage, of abrasion, of corrosion, and of incorrect attachment. n Replace the sensor Verify that the repair eliminates the problem. 4. Clear all logged diagnostic codes. sTOP Test Step 9. Verify the Active Diagnostic Code A. Tum the keyswitch to the OFF position. B, Wait for 15 seconds. C. Tum the keyswitch to the ON position, D. Verify that the diagnostic code is still active. Expected Result: The following diagnostic code is active. + CID 91-FMI 08 Throttle Position signal abnormal Results + OK- The diagnostic code is active. Repair: The sensor is bad. 1. Replace the sensor. 2. Verify that the repair eliminates the problem. 3. Clear all logged diagnostic codes. STOP + Not OK - The diagnostic code is not active. The problem is not present at this time. hips:sis.cat.com sisweblsiswebtechdcctechdoc_ print pagejspreturrt= iswebsiswehprosteisearcnproductheadernforamesetisp&calledpage... 12/18Repair: Clear all logged diagnostic codes. STOP Test Step 10, Check Programmable Parameters A. Conneet the Caterpillar Electronic Technician (ET) to the data link connector. B, Tum the keyswitch to the ON position. C. Make sure that the "Direct Fuel Control Mode" parameter is programmed to "Enabled". D. Verify that the "Throttle Position Sensor” parameter is programmed to "Not Installed” and verify that the "Desired Speed Input Configuration” parameter is programmed to "PWM". Expected Result: The parameters are programmed correctly. Result + OK.- The parameters are programmed correctly. Proceed to Test Step 11. + Not OK - The parameters are programmed incorrectly. Repair: Program the following parameters © Program the "Direct Fuel Control Mode" parameter to "Enabled" © Program the "Throttle Position Sensor" parameter to "Not Installed” © Program the "Desired Speed Input Configuration" parameter to "PWM" Verify that the repair eliminates the problem. STOP Test Step 11. Inspect Electrical Connectors and Wiring ero ccrrr--H-- > 1 caren ta ro 1 I nueter I [| Switches +Battery| 4 A +Batlery U Battery] 6 6 ~Botlery L [2-209 ek apse ¢ Covernar 1 | 9-209 ma —trput] 5 ) Governor punt ecw 1 Throttle Signal 12 £ ot 907-6 [oe 4 throttle Signal i) 1 POL/u6T toooo eee 4 Mustration 9 200923437 ‘Schematic for direct fuel control hips:sis.cat.com sisweblsiswebtechdcctechdoc_ print pagejspreturrt= iswebsiswehprosteisearcnproductheadernforamesetisp&calledpage... 1318Pins. 7-12 1-6 olo fem me elo o Q|o Q|O o/O/H oO H\O|O CURRENT to PWM CONVERTER INPUT: 8-208 mA ourPUT, G-70% (acTIvE isu) © e 2 ho aaaz Jo—cvreur Mlustration 10 200858489 Current to PWM Converter ‘A, Turn the keyswitch to the OFF/RESET position. B, Check the connectors and wiring for the following problems: damage, corrosion, abrasion and incorrect attachment. Pay close attention to the following areas: o JPL 3CM connector © J61/P61 Customer connector © Hardware for the Direct Fuel Control © Wiring for the Direct Fuel Control Refer to Troubleshooting, "Electrical Connectors - Inspect" for more information. Expected Result: htps:sis.cat.comisisweblsiswebtechdcctechdoc_prnt pagejepreturst= swebisiswehproctcisearchiproductheaderrftameset|spicalledpage. wie‘The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment, Results: * OK- Proceed to Test Step 12. + Not OK- 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.Clear all logged diagnostic codes. STOP ‘Test Step 12. Check the Voltage Supply to the Converter A. Tum the keyswitch to the ON position. B. Measure the voltage across pin 4 (+ Battery) and pin 6 (- Battery) of the converter. Expected Result: The voltage should be between 22 VDC and 27 VDC. Results: * OK- The converter is receiving the proper supply voltage. Proceed to Test Step 14. + Not OK - The converter is not receiving the proper supply voltage. Proceed to Test Step13. Test Step 13. Measure No-Load Battery Voltage ‘A. Measure the no-load battery voltage at the battery posts. Note: Load test the batteries with the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of the 4C-4911 Battery Load Tester " and Special Instruction, SEHS7633, "Battery Test Procedure" for further assistance. Expected Result: The no-load voltage should be at least 11.0 VDC for a 12 Volt system and the no-load voltage should be at least 22.0 VDC for a 24 Volt system. The batteries should also pass the load test. Results: * OK - The battery is OK. Repair: There is a problem in the wiring between the battery and the converter. Inspect the wiring and repair the wiring. STOP + Not OK - The battery is not OK. Repair: Replace the battery. Verify that the repair eliminates the problem, hips:sis.cat.com sisweblsiswebtechdccechdoc_prnt pagejp?rturrrl=Isiswebisiswebpracucisearcriproductheaderrforamesetisp&calldpage.. 15/18STOP Test Step 14. Check the Current Input to the Converter A. Measure the current (mA) across pin 1 and pin 3 of the converter. B. Move the throttle from the low idle position to the high idle position. Expected Result: ‘The current is 0 mA at low idle and the current is 200 mA at high idle. Results: + OK- The converter is receiving the proper input. Proceed to Test Step 15 + Not OK - The converter is not receiving the proper input. Repair: Make sure that the governor is tuned on, Check the wiring between the converter and the governor. Repair the wiring, STOP ‘Test Step 15. Measure the Duty Cycle at the Converter A. Tum the keyswitch to the ON position. B. Measure the duty cycle between pin 12 (throttle signal) and engine ground. C. Move the throttle from the low idle position to the high idle position. Expected Result: The duty cycle should be between 5.0 percent and 10.0 percent when the throttle is at low idle. The duty cycle should be 90.0 percent to 95.0 percent when the throttle is at high idle. Results: + OK- The duty cycle is within the specified range. Proceed to Test Step 16. + Not OK - The duty cycle is not within the specified range. Repair: Verify the results. Replace the converter. Verify that the repair eliminates the problem. STOP Test Step 16, Measure the Duty Cycle at the ECM. A. Turn the keyswitch to the ON position, B. Measure the duty cycle between P1-66 and engine ground. C. Move the throttle from the low idle position to the high idle position. Expected Result: ‘The duty cycle should be between 5.0 percent and 10.0 percent when the throttle is at low idle. The duty hips:sis.cat.com siswebisiswebtechdccechdoc_prnt pagejsp?rturrrl=Isiswebisiswebpracucisearcriproductheaderrfotamesetisp&calledpage.. 1818cycle should be 90.0 percent to 95.0 percent when the throttle is at high idle. Results: + OK- The duty cycle is within the specified range. Repair: The ECM is bad. Temporarily install a test ECM, If the problem is corrected install the suspect ECM. If the problem returns, permanently install the new ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM STOP + Not OK - The duty cycle is not within the specified range. Proceed to Test Step 17. ‘Test Step 17. Check for Short Circuits in the Wi g Harness A. Tum the keyswitch to the OFF/RESET position. B. Disconnect the J1/P1 ECM connector. C. Measure the resistance between P1-66 and engine ground. Expected Result: ‘The resistance should be greater than 20,000 ohms. Results: * OK- There are no short circuits in the wiring harness. Proceed to Test Step 18 + Not OK - There is a short circuit in the wiring hamess. Repair: Repair the wiring, Verify that the repair eliminates the problem. STOP Test Step 18. Check for Open Circuits in the Wiring Harness A. Disconnect the J1/P1 ECM connector and pin 12 of the converter. B. Measure the resistance between pin 12 of the converter and P1-66, Expected Result: ‘The resistance should be less than 5 ohms. Results: * OK- There are no open circuits in the wiring hamess, Repair: The direct fuel control is working properly. Continue to troubleshoot until the problem is, solved. STOP + Not OK- Phere is a open circuit in the wiring hamess. hisses cat.com siswebisiswebtechdccechdoc_prnt pagesp?rturrul=Isiswebisiswebpracucisearcriproductheaderrfotamesetisp&calledpage.... 17/18Repair: Repair the wiring. Verify that the repair eliminates the problem. sTOP Dirsitos Autorais 1993 = 2016 Caterilar Inc. Fr Jen 22 20%6 22:15:39 GHT-0300 (Hore oficial do Basi) ‘Todos os Diretios Reservados. Brea) fe Paiclar Para ticendads SIS. hips:sis.cat.com siswebisiswebtechdccechdoc_prnt pagejp?rturrurl=Isiswsbisiswebpracucisearchiproductheaderrfotamesetisp&calldpage.. 18/18