02/08/2022 14:42 SIS 2.

2010/12/15 Throttle Switch Circuit - Test (RENR5089-33)

SMCS - 7332 i04173669 

System Operation Description:

This procedure covers the following diagnostic codes:

91-8 Throttle Position signal abnormal

Note: A false 98-1 diagnostic code can be generated when the machine backup switch is switched to the manual position. The message "BACK
UP SWITCH ON" or "LIMITED MOBILITY MODE" appears on the display in the cab. When the switch is on, the engine speed can be controlled
with another switch that overrides the rotary throttle switch. The 98-1 diagnostic code becomes deactivated when the backup switch is moved to
the automatic position.

The throttle switch provides the operator with the ability to select the desired engine speed. The throttle switch is a rotary switch with ten positions.
The throttle switch is connected to the four switch inputs of the engine and hydraulic pump controller. A throttle command is sent to the engine
Electronic Control Module (ECM) from the engine and hydraulic pump controller. The throttle command is referred to as a duty cycle or as a PWM
signal. The throttle command is valid when the following conditions exist:

The duty cycle is between 5 percent and 95 percent.

The PWM signal is 1.228 kHz ± 150 Hz.

When a diagnostic code is generated, the ECM ignores the throttle command. The desired engine speed is set to the last valid speed that was
recognized by the ECM. When a problem is detected with the throttle signal, the throttle backup switch is enabled. The operator can use the throttle
backup switch to set the desired engine speed. If the throttle backup switch is held in the ACCEL position, the desired engine speed will increase
200 rpm per second. If the throttle backup switch is held in the DECEL position, the engine speed will decrease 200 rpm per second.

Illustration 1 g02364936
Schematic

Table 1 shows continuity between the contacts of the throttle position switch in each position.

Throttle Position Switch 

Position  Contacts 
1  COM, S1 
2  COM, S1, S2 
3  COM, S2 
4  COM, S2, S3 
5  COM, S1, S2, S3 
6  COM, S1, S3 
7  COM, S3 
8  COM, S3, S4 
9  COM, S1, S3, S4 
10  COM, S1, S2, S3, S4 

Table 1

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02/08/2022 14:42 SIS 2.0

Illustration 2 g01120703
P1 ECM connector
(P1-5) Digital return
(P1-22) Throttle backup switch
(P1-23) Throttle backup switch
(P1-66) Throttle command

Test Step 1. Inspect Electrical Connectors and Wiring

A. Turn the keyswitch to the OFF position.

B. Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit.

C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that is associated with the active diagnostic code.

D. Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

E. Check the harness and wiring for abrasions and for pinch points from the sensors back to the ECM.

Expected Result:

All connectors, pins, and sockets are coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.

Results:

OK - The harness and wiring are OK. Proceed to Test Step 2.

Not OK - There is a problem in the connectors and/or wiring.

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 coupled.

Verify that the repair eliminates the problem.

STOP

Test Step 2. Check for Active Diagnostic Codes

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02/08/2022 14:42 SIS 2.0

A. Connect Caterpillar Electronic Technician (ET) to the service tool connector.

B. Turn the keyswitch to the ON position.

C. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

Expected Result:

No diagnostic codes are active.

Results:

OK - No diagnostic codes are active.

Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to
Troubleshooting, "Electrical Connectors - Inspect".

STOP

Not OK - A 91-08 diagnostic code is active at this time. Proceed to Test Step 3.

Test Step 3. Check the Throttle Signal on Cat ET

A. Turn the keyswitch to the ON position.

B. Observe the status of "Throttle" on Cat ET.

C. Turn the throttle switch and observe the status of "Throttle" on Cat ET.

D. Turn the keyswitch to the OFF position.

Expected Result:

The throttle varies from 0 to 100 percent.

Results:

OK - The throttle varies from 0 to 100 percent. The throttle and circuitry are operating correctly.
Repair: If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".

STOP

Not OK - The throttle signal did not vary from 0 to 100 percent. Proceed to Test Step 4.

Test Step 4. Check the Throttle Command at the Engine and Hydraulic Pump Controller

A. Remove the wire F889-WH(White) from terminal 44 of the engine and hydraulic pump controller.

B. Turn the keyswitch to the ON position.

C. Use a multimeter to monitor the percent duty cycle of the throttle command. Connect the multimeter between terminal 44 of the engine and
hydraulic pump controller and engine ground. Adjust the throttle switch from the low idle position to the high idle position.

D. Turn the keyswitch to the OFF position.

E. Replace all wires to the original configuration.

Expected Result:

At low idle, the duty cycle is between 5 percent and 10 percent. At high idle, the duty cycle is between 90 percent and 95 percent.

Results:

OK - The throttle command is correct. Proceed to Test Step 5.

Not OK - The throttle command is not correct. There may be a problem with the throttle switch or the engine and hydraulic pump controller.
Repair: If a problem is suspected with the throttle position switch, refer to Table 1 for information the switch contacts in each position.

If a problem is suspected with the engine and hydraulic pump controller, refer to the System Operation manual and the Testing and Adjusting
manual for the machine.

STOP

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02/08/2022 14:42 SIS 2.0

Test Step 5. Check the Throttle Command at the ECM

A. Turn the keyswitch to the OFF position.

B. Disconnect the J1/P1 ECM connector.

C. Remove the wire F889-WH(White) from ECM connector P1-66.

D. Reconnect the ECM connectors.

E. Turn the keyswitch to the ON position.

F. Use a multimeter to monitor the percent duty cycle of the throttle command. Connect the multimeter between the wire that was removed from
ECM connector P1-66 (throttle command) and engine ground. Adjust the throttle switch from the low idle position to the high idle position.

G. Turn the keyswitch to the OFF position.

H. Replace all wires to the original configuration.

Expected Result:

At low idle, the duty cycle is between 5 percent and 10 percent. At high idle, the duty cycle is between 90 percent and 95 percent.

Results:

OK - The throttle command is correct. The ECM is not processing the command properly. Verify that the ECM is receiving the correct battery
voltage. If the ECM is receiving the correct battery voltage, replace the ECM.
Repair: Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.

STOP

Not OK - The throttle command is not correct.

Repair: There is a problem in the harness or connectors between the engine and hydraulic pump control and the ECM. Repair the circuit.
Verify that the repair eliminates the problem.

STOP

A3R1-UP, AWN1-UP, AZP1-UP, B6H1-UP, BFC1-UP, BYE1-UP, BYS1-UP, C3N1-UP, C4H1-UP, C5K1-UP, C7K1-UP, C8L1-UP, C9M1-UP, CJM1-
UP, CJX1-UP, CZF1-UP, D3D1-UP, DAP1-UP, DBH1-UP, DFP1-UP, DJF1-UP, DTS1-UP, DTZ1-UP, E4K1-UP, EAH1-UP, EBM1-UP, ECH1-UP,
EDF1-UP, EDX1-UP, EFT1-UP, EJC1-UP, ERK1-UP, ERN1-UP, ETE1-UP, FAR1-UP, FFK1-UP, GBR1-UP, GE81-UP, GGE1-UP, GJA1-UP, GPB1-
UP, GPK1-UP, GTN1-UP, H3D1-UP, H3K1-UP, H3N1-UP, HAS1-UP, HHK1-UP, HPB1-UP, J2F1-UP, J6D1-UP, J8D1-UP, J9D1-UP, JAT1-UP, JBF1-
UP, JBT1-UP, JGK1-UP, JHJ1-UP, JJG1-UP, JJM1-UP, JKR1-UP, JLP1-UP, JLS1-UP, JLX1-UP, JRX1-UP, JTN1-UP, JWR1-UP, JZR1-UP, KAB1-
UP, KAY1-UP, KBE1-UP, KDG1-UP, KDJ1-UP, KGG1-UP, KHX1-UP, KKT1-UP, KPM1-UP, KRE1-UP, L2K1-UP, L5G1-UP, L5K1-UP, L5X1-UP,
LAB1-UP, LAL1-UP, LDR1-UP, LEM1-UP, LMG1-UP, LRM1-UP, M3M1-UP, M3N1-UP, M4T1-UP, MBR1-UP, MCL1-UP, MDS1-UP, MEY1-UP,
MFA1-UP, MKR1-UP, MNB1-UP, MND1-UP, MPL1-UP, MWP1-UP, MXL1-UP, MYG1-UP, MYP1-UP, NAC1-UP, NAH1-UP, NBD1-UP, PAL1-UP,
PCK1-UP, PCW1-UP, PEH1-UP, PEL1-UP, PGW1-UP, PJM1-UP, PKE1-UP, PPN1-UP, PRF1-UP, PTB1-UP, PYT1-UP, R2D1-UP, RAS1-UP, RBR1-
UP, RDA1-UP, RJK1-UP, RMX1-UP, RSK1-UP, SCR1-UP, SCY1-UP, SSA1-UP, SWF1-UP, SYM1-UP, T2D1-UP, T2S1-UP, T2Y1-UP, THJ1-UP,
TLY1-UP, TPM1-UP, TRH1-UP, TSN1-UP, TZL1-UP, W3K1-UP, WDC1-UP, WDK1-UP, WET1-UP, WLT1-UP, WRK1-UP, XBH1-UP, XDB1-UP,
YCF1-UP, YFW1-UP, ZCT1-UP, ZML1-UP, ZZR1-UP

PPW-80043209
2022/08/02
12:42:18+02:00
i02400678
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