WOODWARD GOVERNOR SERVICE MANUAL FOR CATERPILLAR G330 Caterpillar

Service Menu Introduction

The PC Service Tool consists of a list of parameters grouped under several service headers. You step through the headers sequentially either forward or backward; when you get to the last (first) header, the next step takes you to the first (last) header. Similarly, when you step down through each header parameter, when you get to the last entry, the next step takes you back to the first entry. Service headers are displayed in CAPITAL letters, and parameters are displayed in lowercase letters.

The following pages show the service list for the 8400-504 DMMP control, with a brief explanation of each parameter.

Service Headers

The ACTUATOR MONITOR display will depend on the calibration mode selected, automatic or manual, in the Configure header.

NOTE: Only one output header, either speed or position, will be displayed, either speed switch 1 or position switch 1 and either speed switch 2 or position switch 2. The selection is done in the Configure header.

Service Header Functions

Minimum Speed Governor

Engine Speed (RPM)

< 0.0 - 3000 RPM> The engine speed is the actual engine speed at that moment.

Minimum Gain

< 0.0001 - 20.0> * The minimum gain is the gain of the minimum governor speed loop. The gain is the rate at which the DMMP control responds to a speed error. See Chapter 7 for dynamics adjustments.

Minimum Stability

< 0.0001 - 10.0> * The minimum stability is the stability of the minimum governor speed loop. The stability is the amount of dampening in the speed loop. See Chapter 7 for dynamics adjustments.

Minimum Actuator Compensation

< 0.0001 - 10.0> * The minimum actuator compensation is the actuator compensation of the minimum governor speed loop. Actuator compensation compensates for the delay in the fuel system and actuator. See Chapter 7 for dynamics adjustments.

Low Idle Set Point (RPM)

< 100 RPM - 1000 RPM> * The low idle set point is the speed reference for the minimum governor at 0% actuator output. The actual minimum speed reference is a point on the line with the low idle and peak idle speeds as its endpoints.

Peak Idle Set Point (RPM)

< 100 RPM - 1000 RPM> * The peak idle set point is the speed reference for the minimum governor at 100% actuator output. The actual minimum speed reference is a point on the line with the low idle and peak idle speeds as its endpoints.

Maximum Speed Governor

Engine Speed (RPM)

< 0.0 RPM - 3000 RPM> The engine speed is the actual speed of the engine at that moment.

Maximum Gain

< 0.0001 - 20.000> * The maximum gain is the gain of the maximum governor speed loop. The gain determines how fast the DMMP control responds to a speed error. See Chapter 7 for more information.

Maximum Stability

< 0.0001 - 10.000> * The maximum stability is the stability of the maximum governor speed loop. The stability is the amount of dampening in the speed loop. See Chapter 7 for more information.

Maximum Actuator Compensation

< 0.0001 - 10.000> * The maximum actuator compensation is the actuator compensation for the maximum governor. Actuator compensation compensates for the delay in the actuator and fuel system. See Chapter 7 for more information.

High Idle Set Point (RPM)

< 1000 RPM - 3000 RPM> * The high idle set point is the speed reference for the maximum governor at 0% actuator. The actual speed reference for the maximum governor is a point on a line with the high idle and rated speed set points at the ends. NOTE-EPA restrictions do not allow this setpoint to be adjusted by the end user. This setpoint is not tunable in the customer PC Service.

Rated Set Point (RPM)

< 1000 RPM - 3000 RPM> * The rated set point is the speed reference for the maximum governor at 100% actuator. The actual speed reference for the maximum governor is a point on a line with the high idle and rated speed set points at the ends. NOTE-EPA restrictions do not allow this setpoint to be adjusted by the end user. This setpoint is not tunable in the customer PC Service.

PTO Governor

PTO Set Point (RPM)

< 100 RPM - 3000 RPM> * The PTO set point is the speed reference for the PTO governor. The DMMP control controls the engine at this speed when the PTO contact is closed. The transmission must be in neutral.

PTO Gain

< 0.0001 - 20.000> * The PTO gain is the gain of the PTO governor. The gain determines how fast the engine responds to a speed error. The PTO and minimum governor use the same stability and actuator compensation. To achieve optimal PTO governor performance, the minimum governor dynamics may need to be adjusted, but this also affects the idle speed performance.

PTO Delay (SEC)

< 0 - 20 SEC> * The PTO delay is the amount of time after the PTO contact is opened before the PTO is actually disabled.

PTO Contact

< TRUE - FALSE> The PTO contact indicates the status of the PTO select input. A TRUE indication activates the PTO control feature of the DMMP control.

NOTE: TRUE indicates + Battery voltage applied to the input pin, and FALSE indicates no voltage applied to the input pin.

Foot Pedal

Foot Pedal Position (%)

< 0.0% - 100%> The foot pedal position is the readout in percent based on the foot pedal sensor voltage at the DMMP control. 0.0 volts in = 0.0%, and 5.0 volts in = 100%. The foot pedal input has high and low fault trip points based on the minimum and maximum foot pedal set points.

Minimum Foot Pedal (%)

< 0.0% - 50.0%> * The minimum foot pedal is the position of the foot pedal at its minimum position. This value should be set to the value seen in the foot pedal position window when the foot pedal is at its fully relaxed position. The low foot pedal fault trip point is determined by the range of the foot pedal (maximum foot pedal - minimum foot pedal = range). The range is multiplied by 0.10 and the result is subtracted from the minimum foot pedal. We recommend that the lowest minimum value be 10% or greater.

Maximum Foot Pedal (%)

< 50.0% - 100%> * The maximum foot pedal is the position of the foot pedal at its maximum position. This value should be set to the value seen in the foot pedal position window when the foot pedal is fully depressed position. The high foot pedal fault trip point is determined by the range of the foot pedal (maximum foot pedal - minimum foot pedal = range). The range is multiplied by 0.10 and the result is added to the maximum foot pedal. We recommend that the highest maximum value be 90% or less.

Door Interlock Contact

< TRUE - FALSE> The door interlock contact indicates the status of the door interlock switch installed on the bus door. TRUE indicates that the door is closed, and FALSE indicates that the door is open. The door interlock disables the foot pedal input and the DMMP control is forced to go to idle control when the door is open.

Idle Validation Contact

< TRUE - FALSE> The idle validation contact indicates the status of the idle validation contact on the foot pedal. TRUE indicates that the foot pedal is off the idle position, and FALSE indicates that the foot pedal is at the idle position. When the contact is open, the foot pedal input is disabled and the DMMP control is forced to go to idle control. The idle validation contact provides added safety by idling the vehicle should a foot pedal failure try to overspeed the vehicle. If an idle validation contact is not used, the input pin should be left open and the idle validation enable set t false.

Idle Validation Enable

< TRUE - FALSE> * The idle validation enable is used to turn the idle validation function on or off. TRUE activates the feature and the DMMP control controls the engine accordingly. FALSE disables the feature and the DMMP control uses the default foot pedal control mode that looks strictly at the foot pedal position. The default mode functions the same as the idle validation mode otherwise.

Transmission Signal

Transmission Signal (VOLT)

< 0.0 - 6.0 Volts> The transmission signal is the actual output voltage sent to the transmission based on the foot pedal position. This signal can be set to any range between the 0 to 6 volt limit. The output is set by the next four set points. The transmission signal is also capable of driving a 4 to 20 mA current (1.0 to 5.0 Vdc) if the transmission input impedance is 249 ohms.

Minimum Output (VOLT)

<0.0 - 6.0 Volts> * The minimum output is the voltage output when the foot pedal is at the minimum foot pedal, below.

Minimum Foot Pedal (%)

<0.0% - 100%> * The minimum foot pedal is the position of the foot pedal that corresponds to the minimum output voltage, above. This is not the same as the minimum foot pedal position set in the FOOT PEDAL header, but typically they are set to the same value.

Maximum Output (VOLT)

<0.0 - 6.0 Volts> * The maximum output is the voltage output when the foot pedal is at the maximum foot pedal, below.

Maximum Foot Pedal (%)

<0.0% - 100%> * The maximum foot pedal is the position of the foot pedal that corresponds to the maximum output voltage, above. This is not the same as the maximum foot pedal position set in the FOOT PEDAL header, but typically they are set to the same value.

Actuator Monitor (Automatic)

Actuator Output (%)

<0.0% - 100%> The actuator output is the actual output signal going to the actuator. The signal should stay within the range set by the minimum and maximum actuator found (see below). The output percent corresponds to a matching actuator position signal. If the two signals do not match within 5.0 seconds of a new command, a blocked actuator fault occurs and the DMMP control attempts to shut down the engine.

Actuator Position (%)

<0.0% - 100%> The actuator position is the actual actuator position feedback percent seen by the DMMP control. The nominal range is 5% at the minimum stop and 95% at the maximum stop of the actuator. The maximum range of the position signal will always be 95%, however, calibration tolerances allow the range to fall anywhere in the 0% - 100% limits. An actuator position fault will occur if the position falls outside the limits for 0.5 seconds or longer.

Minimum Actuator Found (%)

<0.0% - 10%> The minimum actuator found is the physical stop measured at the minimum fuel position of the actuator. The typical value is 5%. The minimum stop is set during the first 0.5 second of control operation. A calibration error value is also recorded during this process.

Maximum Actuator Found (%)

<90% - 100%> The maximum actuator found is the physical stop measured at the maximum fuel position of the actuator. The typical value is 95%. The maximum actuator is set the first time the actuator command goes above 90% for 1.0 second or longer; otherwise, the value is set to 100% plus the calibration error found during the minimum stop calibration.

Actuator Monitor (Manual)

Actuator Output (%)

<0.0% - 100%> The actuator output is the actual output signal going to the actuator. The signal should stay within the range set by the minimum and maximum actuator (see below). The output percent corresponds to a matching actuator position feedback signal. If the two signals do not match within 5.0 seconds of a new command, a blocked actuator fault occurs and the DMMP control attempts to shut down the engine.

Actuator Position (%)

<0.0% - 100%> The actuator position is the actual actuator position feedback percent seen by the DMMP control. The nominal range is 5% at the minimum stop and 95% at the maximum stop of the actuator. The maximum range of the position signal will always be 90%, however, calibration tolerances allow the range to fall anywhere in the 0% - 100% limits. An actuator position fault will occur if the position falls outside the limits for 0.5 seconds or longer.

Minimum Actuator (%)

<0.0% - 50%> * The minimum actuator is used to limit the minimum position of the actuator. The minimum position should be adjusted so that the actuator is just on the minimum fuel stop of the throttle body. Make sure the butterfly is not acting as the stop, because the actuator is capable of damaging the butterfly or the bore.

Maximum Actuator (%)

<50% - 100%> * The maximum actuator is used to limit the maximum position of the actuator. The maximum position should be adjusted so that the actuator is just on the maximum fuel stop of the throttle body.

NOTE: Only one of the output headers below (either speed or position) will be displayed, either speed switch 1 or position switch 1, and either speed switch 2 or position switch 2.

Speed Switch 1

Speed Switch 1 Make

<0 - 3000 rpm> * This value is the activation point for the speed switch output (output 1).

Speed Switch 1 Break

<0 - 3000 rpm> * This value is the deactivation point for the speed speed switch output (output 1).

Speed Switch 1 Status

<True/False> This indicates the current status of the speed switch output (output 1). True is active (Battery Voltage) and false is inactive (No Signal).

Position Switch 1

Position Switch 1 Make

<0 - 100%> * This value is the activation point for the position switch output (output 1), either foot pedal or actuator position.

Position Switch 1 Break

<0 - 100%> * This value is the deactivation point for the position switch output (output 1), either foot pedal or actuator position.

Position Switch 1 Status

<True/False> This indicates the current status of the position switch output (output 1). True is active (Battery (Voltage) and false is inactive (No Signal).

Speed Switch 2

Speed Switch 2 Make

3lt;0 - 3000 rpm> * This value is the activation point for the speed switch output (output 2).

Speed Switch 2 Break

<0 - 3000 rpm> * This value is the deactivation point for the speed switch output (output 2).

Speed Switch 2 Status

<True/False> This indicates the current status of the speed switch output (output 2). True is active (Battery Voltage) and false is inactive (No Signal).

Position Switch 2

Position Switch 2 Make

<0 - 100%> * This value is the activation point for the position switch output (output 2), either foot pedal or actuator position.

Position Switch 2 Break

<0 - 100%> * This value is the deactivation point for the position switch output (output 2), either foot pedal or actuator position.

Position Switch 2 Status

<True/False> This indicates the current status of the position switch output (output 2). True is active (Battery Voltage) and false is inactive (No Signal).

Fault List

NOTE: TRUE indicates a fault is present and FALSE indicates no fault is present.

No Faults Detected

<TRUE - FALSE> No Faults Detected indicates that there are no active faults.

Actuator Position OOR - High

<TRUE - FALSE> Actuator Position OOR (out of range) High indicates that the position percentage went above 105% for 0.5 second or longer.

Actuator Position OOR - Low

<TRUE - FALSE> Actuator Position OOR (out of range) Low indicates that the position percentage went below 0.0% for 0.5 second or longer.

Actuator Calibration Error

<TRUE - FALSE> Actuator Calibration Error indicates that the automatic calibration routine detected an error and the minimum and maximum actuator stop points are not valid.

Blocked Actuator

<TRUE - FALSE> Blocked Actuator indicates that the position signal did not track the command for 5.0 seconds or longer.

Actuator Fault

<TRUE - FALSE> Actuator Fault indicates that the hardware detected a fault in the actuator, wiring, or the DMMP control itself.

Sensor Supply Voltage OOR - High

<TRUE - FALSE> Sensor Supply Voltage OOR High indicates that the +5 volt supply went above 5.25 volts for 0.5 second or longer.

Sensor Supply Voltage OOR - Low

<TRUE - FALSE> Sensor Supply Voltage OOR Low indicates that the +5 volt supply went below 4.75 volts for 0.5 second or longer.

Foot Pedal OOR - High

<TRUE - FALSE> Foot Pedal OOR High indicates that the foot pedal percentage went above the high limit as determined by the minimum and maximum foot pedal settings for 0.5 second or longer.

Foot Pedal OOR - Low

<TRUE - FALSE> Foot Pedal OOR Low indicates that the foot pedal percentage went below the low limit as determined by the minimum and maximum foot pedal settings for 0.5 second or longer.

Idle Validation Fault

<TRUE - FALSE> Idle Validation Fault indicates that the foot pedal percentage went above 50% for 0.5 second or longer while the idle validation contact was open. This fault is enabled only when the idle validation contact is enabled.

Discrete Output Fault

<TRUE - FALSE> Discrete Output Fault indicates that the hardware detected a short at one of the discrete outputs.

Engine Speed Fault

<TRUE - FALSE> Engine Speed Fault indicates that the DMMP control does not see an engine speed signal. This fault is valid only if the engine is running.

Engine Overspeed

<TRUE - FALSE> Engine Overspeed indicates that the engine has been oversped.

Fault Logger

NOTE: The fault logger records a count of the active faults that were detected since the last time the logger was cleared. The maximum count for any listing is 5. See the Fault List above for fault definitions.

Actuator Position OOR - HighActuator Position OOR - LowActuator Calibration ErrorBlocked ActuatorActuator FaultSensor Supply Fault OOR - HighSensor Supply Fault OOR - LowFoot Pedal OOR - HighFoot Pedal OOR - LowIdle Validation FaultDiscrete Output FaultEngine Speed FaultEngine OverspeedClear Fault Log

<TRUE - FALSE> * This tunable is used to clear all of the fault log counts to zero. Tune the value to TRUE, then back to FALSE.

Configure Menu

The PC Service Tool also provides a configure menu that operates the same way as the service menus (see Figure 3-2). The configure menu is accessed by pressing an upper case "C" while operating in PCSVC. The configure menu contains setpoints that should not be adjusted when the engine is running. The configure menu requires that the engine be shut down before entering the menu. Attempting to access the configure menu while the engine is running will cause the DMMP control to force the actuator to minimum position.

Configure Headers

Engine MPU

* Gear Teeth

Calibration Select

* Auto Actuator Calibration

Switch Select

* Switch 1 Select

* Switch 2 Select

Configure Header Functions

Engine MPU

Gear Teeth

<10-500> * Gear Teeth refers to the number of gear teeth on the speed sensing gear. The speed sensing gear should be on the crankshaft.

Calibration Select

Auto Actuator Calibration

<TRUE - FALSE> * Auto Actuator Calibration selects the calibration mode for the actuator minimum and maximum stops. TRUE indicates that the DMMP control will attempt to calibrate the actuator itself. This will occur during the first 0.5 second of operation and a small kick in the actuator movement will be seen during this time. False indicates that the actuator stops will need to be set manually with the PC Service.

Switch Select

Switch 1 Select

<1 - 3> * This value is used to determine the switch 1 output operating mode. Mode 1 is speed switch, mode 2 is foot pedal position switch, and mode 3 is actuator (throttle) position switch.

Switch 2 Select

<1 - 3> * This value is used to determine the switch 2 output operating mode. Mode 1 is speed switch, mode 2 is foot pedal position switch, and mode 3 is actuator (throttle) position switch.