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Product: GENERATOR SET
Model: G3520B GENERATOR SET GZP
Configuration: G3520B Generator Set GZP00001-UP
Troubleshooting
G3520B Engines
Media Number -RENR5927-05 Publication Date -01/05/2006 Date Updated -25/05/2006
i01893588
Desired Speed Input (4 - 20 mA)
SMCS - 1901-038
System Operation Description:
Note: For this troubleshooting procedure, the "Desired Speed Input" configuration parameter must be set
to "4-20 mA Input" in the "Service/Configuration" screen of the Caterpillar Electronic Technician (ET).
Do not select "PWM". The master Electronic Control Module (ECM) cannot be configured to accept a
PWM input signal for control of the engine speed.
The selection of the "4-20 mA Input" setting requires a 4 to 20 mA signal for regulation of the desired
engine speed. If the "Desired Speed Input" is set to "0-5 VDC Input", do not use this procedure to
troubleshoot the circuit.
When the desired speed input is correspondingly configured, the master ECM controls the engine speed
according to the 4 to 20 mA current.
The value of the current corresponds to a range of desired engine speeds between minimum high idle
and maximum high idle. The "Minimum Engine High Idle Speed" and the "Maximum Engine High Idle
Speed" are set with the "Service/Configuration" screen of ET. For more information, refer to Systems
Operation/Testing and Adjusting, "Electronic Control System Parameters".
When the "Idle/Rated" switch is in the Rated position, a current value of 4.0 mA corresponds to the
programmed "Minimum Engine High Idle Speed". A current value of 20.0 mA corresponds to
"Maximum Engine High Idle Speed". Current values within this range will vary the desired engine speed
in a linear fashion between "Minimum Engine High Idle Speed" and "Maximum Engine High Idle
Speed".
Current values that are greater than 22.0 mA will activate the "524-03 Desired Engine Speed Sensor
short to +batt" diagnostic code. Current values that are less than 2.0 mA will activate the "524-04
Desired Engine Speed Sensor short to ground" diagnostic code.
The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness.
The next likely cause is a problem with a component. The least likely cause is a problem with the master
ECM.
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Logged diagnostic codes provide a historical record. Before you begin this procedure, use ET to print
the logged codes to a file.
The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting
the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 1 g00993477
Schematic of the 4 to 20 mA desired speed input
Test Step 1. Inspect the Electrical Connectors and Wiring
A. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.
Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".
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Illustration 2 g00985627
Terminal box for the master ECM
(1) 16 amp circuit breaker
(2) J1/P1 connectors for the master ECM
(3) J9/P9 connectors
B. Thoroughly inspect the following components:
ECM J 1/P1 connectors
J 9/P9 connectors on the terminal box
Wiring and the connections between the terminal box and the device that supplies the 4 to
20 mA signal
a. Check the torque of the Allen head screw for the master ECM connectors. The proper
torque is 6 1 Nm (55 9 lb in).
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Illustration 3 g00905060
Harness side of the master ECM P1 connector
(P1-36) +Signal
(P1-37) - Signal
Illustration 4 g00890197
Harness side of the P9 connector
(P9-K) +Signal
(P9-P) - Signal
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the 4 to 20 mA
circuit.
c. Check the harness and wiring for abrasion and pinch points between the device that supplies
the 4 to 20 mA signal and the master ECM.
Expected Result:
All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
Results:
OK - The components are in good condition with proper connections. If you are troubleshooting a
"524-03 Desired Engine Speed Sensor short to +batt" diagnostic code, proceed to Test Step 2. If
you are troubleshooting a "524-04 Desired Engine Speed Sensor short to ground" diagnostic code,
proceed to Test Step 5.
Not OK - The components are not in good condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary.
STOP
Test Step 2. Check for an Open Circuit
A. Remove the two wires ("+" and "-") for the 4 to 20 mA signal from the device that supplies the 4
to 20 mA signal.
B. Install a jumper wire between the two wires ("+" and "-") that were removed from the device that
supplies the 4 to 20 mA signal.
C. Disconnect the P1 connector from the master ECM.
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Illustration 5 g00905071
ECM side of the P1 connector
(P1-36) +Signal
(P1-37) - Signal
D. Use an ohmmeter to measure the resistance between terminals P1-36 and P1-37 on the ECM side
of the P1 connector.
Expected Result:
The resistance is less than 5 ohms.
Results:
OK - The resistance is less than 5 ohms. The circuit is not open.
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Repair: Remove the jumper wire. Insulate the wire leads with electrical tape in order to ensure
that the leads do not create a short circuit.
Proceed to Test Step 3.
Not OK - The resistance is greater than 5 ohms. There is a problem with a connector and/or the
wiring from the P1 connector.
Repair: The problem may be between the P1 connector and the J 9 connector. Alternatively, the
problem may be between the P9 connector and the device that provides the 4 to 20 mA
signal.Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify
that the problem is resolved.
STOP
Test Step 3. Check for a Short Circuit to the +Battery at Terminal P1-36
A. Verify that the engine control is in the OFF/RESET mode and that the 16 amp circuit breaker is
OFF.
B. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal.
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Illustration 6 g00902098
ECM side of the P1 connector
(P1-36) +Signal
(P1-57) +Battery
C. Use an ohmmeter to measure the resistance between terminals P1-36 and P1-57.
Expected Result:
The resistance is greater than 20,000 ohms.
Results:
Yes - The resistance is greater than 20,000 ohms. The wiring from terminal P1-36 is not shorted to
the +battery side. Do not reconnect any connectors. Proceed to Test Step 4.
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No - The resistance is less than 20,000 ohms. There is a problem with a connection and/or the
wiring from terminal P1-36.
Repair: The problem may be between the P1 connector and the J 9 connector. Alternatively, the
problem may be between the P9 connector and the device that provides the 4 to 20 mA
signal.Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify
that the problem is resolved.
STOP
Test Step 4. Check for a Short to Ground at Terminal P1-37
A. Verify that the engine control is in the OFF/RESET position and that the 16 amp circuit breaker is
OFF.
B. Make sure that the leads of the wires for the 4 to 20 mA signal do not create a short circuit.
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Illustration 7 g00902099
ECM side of the P1 connector
(1) Ground strap
(P1-37) - Signal
C. Use an ohmmeter to measure the resistance between ground strap (1) and terminal P1-37.
Expected Result:
The resistance is greater than 20,000 ohms.
Results:
Yes - The resistance is greater than 20,000 ohms. The wiring from terminal P1-37 appears to be
OK.
Repair: Reconnect the P1 connector. Reconnect the two wires ("+" and "-") for the 4 to 20 mA
signal to the device that supplies the 4 to 20 mA signal.
Proceed to Test Step 7.
No - The resistance is less than 20,000 ohms. There is a problem with a connection and/or the
wiring that is connected to P1-37.
Repair: The problem may be between the P1 connector and the J 9 connector. Alternatively, the
problem may be between the P9 connector and the device that provides the 4 to 20 mA
signal.Locate the wire with the short circuit and repair the wire. Verify that the problem is
resolved.
STOP
Test Step 5. Check for a Short Circuit to the +Battery Side at Terminal P1-37
A. Verify that the engine control is in the OFF/RESET mode and that the 16 amp circuit breaker is
OFF.
B. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal.
C. Remove the two wires ("+" and "-") for the 4 to 20 mA signal from the device that supplies the 4
to 20 mA signal. Insulate the wire leads with electrical tape in order to ensure that the leads do not
create a short circuit.
D. Disconnect the P1 connector from the master ECM.
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Illustration 8 g00902100
ECM side of the P1 connector
(P1-37) - Signal
(P1-57) +Battery
E. Use an ohmmeter to measure the resistance between terminals P1-37 and P1-57.
Expected Result:
The resistance is greater than 20,000 ohms.
Results:
Yes - The resistance is greater than 20,000 ohms. The wiring from terminal P1-37 is not shorted to
the +battery side. Do not reconnect any connectors. Proceed to Test Step 6.
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No - The resistance is less than 20,000 ohms. There is a problem with a connection and/or the
wiring from terminal P1-37.
Repair: The problem may be between the P1 connector and the J 9 connector. Alternatively, the
problem may be between the P9 connector and the device that provides the 4 to 20 mA
signal.Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify
that the problem is resolved.
STOP
Test Step 6. Check for a Short Circuit to Ground at Terminal P1-36
A. Verify that the engine control is in the OFF/RESET mode and that the 16 amp circuit breaker is
OFF.
B. Make sure that the ends of the wires for the 4 to 20 mA signal do not create a short circuit.
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Illustration 9 g00902101
ECM side of the P1 connector
(1) Ground strap
(P1-36) +Signal
C. Use an ohmmeter to measure the resistance between ground strap (1) and terminal P1-36.
Expected Result:
The resistance is greater than 20,000 ohms.
Results:
Yes - The resistance is greater than 20,000 ohms. The wiring from terminal P1-36 appears to be
OK. Do not reconnect any connectors. Proceed to Test Step 7.
No - The resistance is less than 20,000 ohms. There is a problem with a connection and/or the
wiring from terminal P1-36.
Repair: The problem may be between the P1 connector and the J 9 connector. Alternatively, the
problem may be between the P9 connector and the device that provides the 4 to 20 mA
signal.Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify
that the problem is resolved.
STOP
Test Step 7. Check the Device that Provides the 4 to 20 mA Signal
Measure the 4 to 20 mA signal according to the literature that is provided by the OEM of the device that
provides the 4 to 20 mA signal. Verify that the correct signal is provided to the master ECM.
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Illustration 10 g00902102
Harness side of the master ECM P1 connector
(P1-36) +Signal
(P1-37) - Signal
Verify the correct 4 to 20 mA signal at terminals P1-36 and P1-37.
Expected Result:
The correct 4 to 20 mA signal is provided to the master ECM.
Results:
Yes - The correct 4 to 20 mA signal is provided to the master ECM. However, the ECM is not
responding correctly to the signal. There may be a problem with the master ECM.
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Repair: It is unlikely that the master ECM is faulty. Exit this procedure and perform this
procedure again. If the problem is not resolved, replace the master ECM according to
Troubleshooting, "Replacing the ECM". Verify that the problem is resolved.
STOP
No - The master ECM is not receiving the correct 4 to 20 mA signal. There is probably a problem
with the device that provides the 4 to 20 mA.
Repair: Service the device that provides the 4 to 20 mA according to the literature that is
provided by the OEM of the device. Verify that the problem is resolved.
STOP
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