6/5/2020 Advanced Full Text Search - KENR5398 - C175-16 and C175-20 Engines for Off-Highway Truck/Tractors

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Troubleshooting
C175-16 and C175-20 Engines for Off-Highway Truck/Tractors
Media Number -KENR5398-25 Publication Date -01/12/2014 Date Updated -16/07/2019

i07418062

Speed Control - Test

SMCS - 7332-038-VF

Use this procedure to troubleshoot a problem with the throttle position sensor. Also, use this procedure if one of the following diagnostic codes is
active or easily repeated.

Table 1
J1939 Code and Description CDL Code and Description Comments
The ECM detects signal voltage that is not in the acceptable
91-3 91-3 range.
Accelerator Pedal Position 1 : Voltage Throttle Position Sensor : Voltage The ECM flags the throttle position as invalid data and a default
Above Normal Above Normal value is used. The engine speed is limited to high idle.
The code is logged.
The ECM detects signal voltage that is not in the acceptable
91-4 91-4 range.
Accelerator Pedal Position 1 : Voltage Throttle Position Sensor : Voltage The ECM flags the throttle position as invalid data and a default
Below Normal Below Normal value is used. The engine speed is limited to high idle.
The code is logged.
91-8 91-8 The PWM signal from the sensor to the ECM is not correct.
Accelerator Pedal Position 1 : Abnormal Throttle Position Sensor : Abnormal The code is logged.
Frequency, Pulse Width, or Period Frequency, Pulse Width, or Period
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Note: Performing steps within this procedure requires the use of a multimeter capable of measuring a PWM duty cycle and frequency. Refer to Table
2 for the tools recommended for the procedure.

Table 2
Recommended Tools
146-4080 Digital Multimeter Gp
7X-1710 Multimeter Probe
326-4904 Adapter Cable As

Table 3
Troubleshooting Test Steps Values Results

1. Check for Codes

Result: A 91 code is active or logged.
A. Connect Cat® Electronic Technician (ET) to the service tool Codes
connector. Proceed to Test Step 2.
B. Determine if a code is active or logged.

2. Check the Signal Frequency and the Duty Cycle at the Sensor Frequency Result: The ECM detects an incorrect frequency on the
throttle signal or an incorrect duty cycle on the throttle signal.
A. Remove electrical power from the engine. Duty The frequency is below 150 Hz or the frequency is above
cycle 1000 Hz. The duty cycle is less than 5 percent or the duty
B. Remove the wire from terminal location C (Throttle position) on cycle is greater than 95 percent.
the wiring harness side of the connector for the throttle position
sensor. Proceed to Test Step 3.

C. Install a 326-4904 Adapter Cable As (3-PIN BREAKOUT) at the Result: The frequency and the duty cycle are within
connector for the throttle position sensor. specifications for the entire range of the pedal.

D. Connect the connector for the throttle position sensor. Repair: Repair or replace the wiring harness.

E. Apply electrical power to the engine.

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If the problem is not resolved, proceed to Test Step 3.

F. Measure the frequency and the duty cycle at the 326-4904 Adapter
Cable As (3-PIN BREAKOUT) between the following terminals:

- B (Digital return) and C (Throttle position)

G. Operate the throttle pedal while making the measurements.

H. Remove electrical power from the engine.

J. Remove the breakout harness.

K. Restore the wiring harness connector to the original configuration.

Result: The supply voltage is above 7.5 VDC at the sensor

connector.
3. Check the Supply Voltage to the Sensor
Repair: The wiring is OK. Replace the sensor.
A. Remove electrical power from the engine.
Verify that the repair eliminated the problem.
B. Disconnect the wiring harness connector for the throttle position
sensor. 7.5 VDC Result: The supply voltage is not above 7.5 VDC at the
sensor connector.
C. Measure the voltage across the following wiring harness connector
terminals: The supply voltage is not reaching the speed control.

- Terminal A (8 V supply) and Terminal B (Digital return) Repair: Repair or replace the wiring harness.

Verify that the repair eliminated the problem.

4. Create a Short at the Throttle Connector Create a Result: A -4 code becomes active.
Short
A. Remove electrical power from the engine. Repair: The wiring is OK. Replace the failed throttle.

B. Install a jumper wire between the appropriate signal and return Verify that the repair eliminated the problem.
wire at the sensor connector to create a short.
Result: A -4 code does not become active.
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- Signal terminal and Return terminal

Proceed to Test Step 5.
C. Connect Cat ET.

D. Use Cat ET to monitor the following codes:

- -4 code

E. Remove electrical power from the engine.

5. Create an Open at the Throttle Connector

A. Remove electrical power from the engine. Result: A -3 code becomes active.

B. Disconnect the appropriate throttle sensor connector. Repair: The wiring is OK. Replace the failed throttle.
Create an
C. Connect Cat ET. Verify that the repair eliminated the problem.
Open
D. Use Cat ET to monitor the following codes: Result: A -3 code does not become active.

- -3 code Proceed to Test Step 6.

E. Remove electrical power from the engine.

6. Check the Supply Voltage to the Sensor 5 VDC Result: The supply voltage is correct.

A. Remove electrical power from the engine. Proceed to Test Step 7.

B. Disconnect the wiring harness connector for the throttle position Result: The supply voltage is not correct.
sensor.
Repair: There is a short in the harness. Repair or replace the
C. Apply electrical power to the engine. wiring harness.

D. Measure the voltage across the appropriate connector terminals. Verify that the repair eliminated the problem.

Note: Refer to the correct wiring schematic for sensor supply

information. Schematic may differ from engine to engine.
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E. Connect the sensor

Result: The wiring failed the Wiggle Test.

7. Perform the Wiggle Test
Repair: There is a problem with the wiring harness. Repair
or replace the wiring harness.
Carefully following this procedure is the best way to identify the root
cause of an intermittent problem.
Verify that the repair eliminated the problem.
A. Connect Cat ET.
Result: The wiring passed the Wiggle Test.
B. Use CAT ET to perform the following test:
Repair: The problem may be intermittent. Inspect the wiring
harness. Refer to Troubleshooting, "Electrical Connectors -
- "Wiggle Test"
Inspect" for additional information.
C. Slowly wiggle the wiring and the connectors between the P2
Test If the wiring looks OK perform the following procedure:
connector and the sensor. Slowly wiggle the wiring and the connectors
between the P1 connector and the sensor. Pay particular attention to
1. Remove electrical power from the engine.
the wiring near each connector. Be sure to wiggle all of the wiring.
2. Disconnect the connectors. Carefully inspect the terminals
D. As you wiggle the wiring look for the following problems:
for proper installation. Make sure that each terminal is clean
and dry.
- Loose connectors or damaged connectors
- Moisture on the connectors or the wiring
3. Insert a pin into each socket. Verify that each socket grips
- Damage that is caused by excessive heat
the pin firmly. Repair any problems.
- Damage that is caused by chafing
- Improper routing of wiring
4. Connect all connectors.
- Damaged insulation
5. Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

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