22/4/2021 SIS 2.

1990/12/31 Prueba y ajuste del sistema electrónico (SENR4527)

SMCS -

Pruebas y ajustes después del reemplazo de

componentes
Cuando se reemplaza cualquiera de los componentes importantes del sistema de control de la unidad de potencia, es necesario realizar ajustes y
/ o pruebas.

1) controlador

2) Válvula reductora proporcional y

3) Sensor de velocidad del motor

4) relé AEC,
5) Interruptor de modo de energía,
6) interruptor AEC y
7) Presostato AEC.

Programas de prueba
El controlador contiene dos programas de prueba, 1 y 2, que se utilizan para comprobar si los componentes de repuesto están correctamente
ajustados y funcionan.

Conjunto de controlador
(1) Pantalla LED. (2) Interruptor 2. (3) Interruptor 1.
Test Programs work while switches 1 (3) and/or 2 (2) are being depressed. Switch 1 is used for Test Program 1 and Switch 2 is for Test Program 2.
Both switches are used at the same time to check the controller after replaced. The controller maintains the normal control mode when neither of
the switches is depressed.

Test Program 1
Test Program 1 can test the five functions that follow.

1. Signal Current To Proportional Reducing Valve

This test checks whether the signal current from the controller sufficiently varies in the whole range needed for correct activation of the proportional
reducing valve. At the same time, this test checks whether the proportional reducing valve processes the change from the signal current to the
power shift pressure.

This test should be done after the controller and/or proportional reducing valve is replaced. Also, this test will help locate a cause when the engine
tends to stall, or not enough operating force or speed is found.

2. Voltage To AEC Relay

This test can check whether the output circuit to the AEC relay is functioning correctly. In actual check of this circuit, however, it is preferable to use
the display of Self-Diagnostic Function Displays code No.5 because of its easiness.

3. Operation Of Power Mode Switch

The signal input from the power mode switch to the controller can be checked which in turn gives an analysis of the power mode condition.

This test should be done after the power mode switch is replaced.

4. Operation Of AEC Switch.

The AEC switch can be checked whether it correctly turns ON/OFF. If no displays of Self-Diagnostic Function Displays code No.7 appear with the
AEC switch in either position of ON or OFF, it indicates that the switch is in the normal condition. In this case, this test is not necessary.

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5. Operation Of AEC Pressure Switch

The AEC pressure switch can be checked whether it correctly turns ON/OFF, when the machine is loaded or unloaded.

This test will help analyze the condition of the AEC pressure switch to locate the cause of Automatic Engine Control (AEC) malfunction.

Test Program 2
The actual characteristics of the proportional reducing valve may vary between reducing valves because reducing valve components such as
solenoid, hydraulic valve, etc. are not perfectly the same. After replacement of a proportional reducing valve, the signal current from the controller
as it was will not keep the power shift pressure as it was.

For this reason, a calibration to the controller memory must be done so that the power shift pressure at high idling could be adjusted to the
specification. This is called "a calibration of standard power shift pressure".

As Test Program 2 is started, the controller outputs seven different values of signal current, which in turn allows the proportional reducing valve to
vary the power shift pressure in seven different values. The controller compares and stores the current setting at the time one of the seven power
shift pressure settings comes closest to the specification.

The stored signal current of the controller is used for the proportional reducing valve to output the standard power shift pressure.

This provides a calibration of the power shift pressure.

This calibration must be done whenever the controller or proportional reducing valve is replaced. In addition, this procedure will help locate a cause
of not enough operating force or speed.

Procedures In Test Programs

Test Program 1
6V4161 Pressure Gauge Kit.6V7070 Multimeter.990050 Test Harness.

Current To Proportional Reducing Valve

1. Disconnect connector (5) to proportional reducing valve (4).

(5) Connector. (6) 990050 Test harness. (7) Multimeter. (8) Pressure gauge.
2. Install Test Harness (6) to measure current through the solenoid.

3. Mount pressure gauge (8) 4000 kPa (580 psi) to tap (9) of the Main pump.

4. Let the engine run at high idle, and confirm LED4 lights.

5. Press switch 1 to put out LED4.

6. while keeping switch 1 pressed check the followings.

a. Multimeter (7) must read approximately 1A and 0.2A in a cycle of four seconds.

b. At the same time, pressure gauge (8) must read approximately 3450 kPa (500 psi) and 980 kPa (140 psi) respectively.

7. Set switch 1 to OFF to light LED4. The controller will return to the control mode.

Output Voltage To AEC Relay

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Connector (CONN1) Of Controller

(10) Socket No.7. (11) Socket No.17.
1. Mount Multimeter across sockets No.7 (10) (SOL.B+) and No.17 (11) (SOL.B-) which are output terminals of CONN1 to AEC relay.

2. Let the engine run at high idle to light LED4.

3. Press switch 1 to put out LED4.

4. While keep switch 1 pressed, check AEC motor activating every 20 seconds to make the engine run at high idle and at AEC activated speed by
turns.

5. Set switch 1 to OFF to light LED4. Then controller will return to the control mode.

Change Power Mode Switch Over

1. Set start switch to ON to light LED4.

2. Press switch 1 on the top of the controller to put LED4 OFF.

3. While keeping switch 1 pressed, operate power mode switch.

If everything is in order, LED1 will light when power mode switch is in the position III. In the position II, LED2 will light. In the position I, LED1 and 2
will light.

AEC Switch ON/OFF

1. Let the engine run at high idle. Release safety lock.

2. Press switch 1 to put out LED4.

3. While keeping switch 1 pressed, set AEC switch to ON. If everything is okay. LED3 will light.

AEC Pressure Switch On/Off

While maintaining the conditions of Step 3 of the above test, move control lever to place pressure switch in the ON mode.

If everything is okay, LED4 will light.

Test Program 2
1. Attach a pressure gauge [4000 kPa (580 psi)] to tap (9) of the main pump.

Main Pump
(9) Tap.
2. Set the power mode switch to the III mode.

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3. Turn the AEC switch OFF.

Start the engine and move the governor control lever to high idle. Check to see that LED4 is ON, indicating that the controller is in operation.

4. Hold switch 2 pressed.

5. The power shift pressure changes in 7 steps. When the pressure reaches 2250 ± 100 kPa (330 ± 14 psi), press switch 1 for about one second.

6. Release switch 2 to complete the calibrating operation.

7. Move a control lever (bucket, for example) full stroke once or twice.

8. Make sure that the power shift pressure is 2250 ± 100 kPa (330 ± 14 psi) when the control lever is in the neutral position. If out of specification,
make adjustment again.

9. Make sure that only LED4 of 1 to 4 lights. This indicates a normal status.

Proportional Reducing Valve

(1) Adjusting nut. (2) Connector. (3) Solenoid. (4) Reducing valve.
A : Passage (power shift pressure).
P : Passage (pilot circuit pressure).
T : Passage (oil tank line).
In rare cases, the above procedure may fail to provide the standard power shift pressure of 2250 ± 98 kPa (330 ± 14 psi) because the relation
between the input current to the proportional reducing valve and the output power shift pressure significantly differs from the planned
characteristics.

If this happens, a calibration to the proportional reducing valve should be done. Turn in or out adjusting nut (1) until correctly calibrated. One turn of
nut (1) changes the pressure approximately 35 kPa (5 psi). To decrease the pressure, tighten nut (1) a maximum of 8 turns. To increase, loosen it a
maximum of 1 1/2 turns.

Ajustment After Replacement Of Components

When any of the following components of the power unit control is replaced, adjustment is required.

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1. Controller

2. Proportional reducing valve

3. Engine speed sensor

Controller
Engine High Idle Input

Engine Control Operation (At High Idle)

(1) Governor control lever. (2) Stop. (3) Governor lever. (4) Lever. (5) Lever. (6) Cable. (7) Stop.

Engine Control Operation (At Low Idle)

(1) Governor control lever. (2) Stop. (3) Governor lever. (4) Lever. (5) Lever. (6) Cable. (7) Stop.
1. Place governor control lever (1) in the low idle position. Make sure that governor lever (3) is placed in the idle position. Lever (4) must be in
contact with stop (7) of lever (5). Adjust cable (6) so that the cable has no slack at two places (shown by

).

2. Place the governor control lever in the high idle position.

Stop (2) must not be in contact with the governor control lever. Adjust the position of stop (2) according to the following procedure:

a) Make sure that lever (3) has moved full travel.

b) Pull lever (1) further and turn lever (4) clockwise until the clearance between lever (4) and stop (7) is 1 mm (0.04"). For this purpose, install a 1
mm thickness gauge in the clearance.

c) Turn stop (2) bolt in until stop (2) is in contact with lever (1). Tighten the lock nut to lock the stop in position.

d) Remove the thickness gauge.

e) Return the governor control lever to the low idle position.

3. Remove the controller cover so that switch 1 (10) and switch 2 (9) can be operated and display (8) can be observed.

Controller Assembly

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(8) LED display. (9) Switch 2. (10) Switch 1.

4. Turn on the start switch.

5. Start the engine and run at full speed.

6. Turn the AEC switch OFF.

7. Press both switches 1 and 2 at the same time and hold for more than three seconds. Release both switches when LEDs 3 and 4 start flashing.
Then press both switches 1 and 2 again for about one second. LED7 will light.

Press switch 1 for three seconds. LED3 will stop flashing and LED4 will remain lit. This indicates that engine high idle speed has been input.

Calibration Of Proportional Reducing Valve

Perform two Test Programs that follow.

* Test Program 1-1 Signal current to PRV* Test Program 2 Calibration of standard power shift pressure

Proportional Reducing Valve

When only the proportional reducing valve is replaced, make adjustments according to the above two test programs.

Engine Speed Sensor (Magnet Pickup)

A magnet pickup that serves as engine speed sensor (1). It is installed in the flywheel housing just under the engine muffler.

Installation Of Engine Speed Sensor

(1) Speed sensor. (2) Harness. (3) Locknut. (4) Flywheel. (5) Ring gear. (6) Housing.
1. After the engine is stopped, slowly tighten speed sensor (1) until its head is in contact with ring gear (5).

2. Back out a half turn [equal to 0.75 mm (0.029 in.)].

3. Tighten lock nut (3) temporarily.

4. Start the engine and run at low idling of about 700 rpm.

5. Make sure that LED9 of the controller is ON.

NOTE: The LED may be difficult to see.

6. If LED9 is not ON, turn down the speed sensor a small amount at a time, while making sure that approximately a third of a turn is not exceeded,
until the LED9 lights.

7. Tighten the lock nut to a torque of 5 N·m (4 lb.ft.).

Test After Replacement Of Components

1. AEC relay

2. AEC switch
3. AEC pressure switch

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When any of above AEC parts is replaced, always check whether AEC is correctly functioning by the following procedure.

a) Place the AEC switch in the OFF position.

b) Start the engine and move the governor control lever to the high idle position to raise the engine speed to 1950 ± 50 rpm.

c) Turn the AEC switch ON and check to be sure that the engine has decreased its speed to 1300 ± 50 rpm.

d) Activate any of controls. Instantly, the AEC should stop its operation and the engine speed should return to the governor control lever setting of
1950 ± 50 rpm.

Change Power Mode Switch

Perform Test Program 1-3.

Controller Input And Output Schematic (Voltage Signals In Normal

Operating Condition) - (6KF1-589, 7DF1-1404)

Controller Input And Output Schematic (Voltage Signals In Normal

Operating Condition) - (6KF590-UP, 7DF1405-UP)

PIP-10611842
2021/04/23
01:49:24-05:00
SENR45270009
© 2021 Caterpillar Inc.

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Caterpillar:
Confidential Green

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