Caterpillar Electronic Locomotive Control System II Caterpillar

Problem Number 6 Engine Speed Not Constant

Usage:

STEP 1. Isolation of Speed Control and Load Control

Test Procedure:

Run engine unloaded. Then run engine loaded.

NOTE: The easiest method to do this is with the reverser. When checking loaded be aware that the locomotive may move. For unloaded test, center the reverser. For loaded test select forward or reverse.

Expected Results:

Constant engine speed in both tests.

STEP 2. Check for proper adjustment of unit-injectors

Test Procedure:

While the engine is running unloaded, listen to the engine for signs that several cylinders are not firing.

Expected Results:

All cylinders are firing.

STEP 3. Isolation of Engine from Governor

Test Procedure:

Run engine unloaded (with reverser centered). Manually hold linkage stationary.

NOTE: Using the manual shutoff lever, apply a small but steady amount of force in the shutoff direction. This procedure removes the governor system from the engine.

Expected Results:

Constant engine speed.

STEP 4.

Check Diagnostic Lamps on Locomotive Control Box

Test Procedure:

With the engine running unloaded, observe the diagnostic lamps which are visible at the Locomotive Control box lid.

Expected Results:

All lamps are OFF.

STEP 5. Manual Linkage Check

Test Procedure:

With engine stopped, check the linkage manually for backlash or binding. See Service Procedure A.

Expected Results:

Linkage has no binding and backlash is acceptable.

STEP 6. Adjust Actuator Needle Valve

Test Procedure:

Make an adjustment of actuator needle valve (CW slows engine response: CCW increases engine response).

NOTE: Do not completely close needle valve setting with engine running. Typical setting is 3/4 turn open (CCW).

Expected Results:

Engine speed becomes constant.

NOTE: Not all actuators used with the Locomotive Control have a needle valve adjustment.

STEP 7. Check Connection Between Control Box and Actuator

Test Procedure:

With engine stopped, disconnect Connector J2 from the Locomotive Control box. While manually shaking the harness and leads at various points between the connector and actuator measure the resistance between pins 1 and 2 of the wiring harness side of Connector J2.

Expected Results:

Measured resistance should be constant and between 30 and 40 ohms.

STEP 8. Check Actuator Oil Pressure Output

Test Procedure:

Remove the test pressure plug from actuator and install 6V2044 Test Pressure Gauge. Now crank the engine and read pressure gauge.

NOTE: For correct pressure range, see ACTUATOR SPECIFICATIONS in Service Procedure D.

Expected Results:

Oil pressure acceptable and constant.

STEP 9. Check Actuator Oil Supply

Test Procedure:

Stop the engine. Verify that amount of oil supply is acceptable. Engine oil sump compartment must be full, oil suction line must be open and must not have any air leaks (i.e., loose fittings or faulty gaskets). Drain must be open to allow good drainage with no back pressure. See Service Procedure B.

Expected Results:

Good oil supply, no drainage problems.

STEP 10. Actuator Coil Resistance Check

Test Procedure:

Disconnect wiring connector from actuator. Put a jumper across pins C and D of connector. Measure the actuator coil resistance across connector pins A and B. (See Service Procedure B Fig.2.)

Expected Results:

Measured resistance to be between 30 to 40 ohms.

STEP 11. Actuator Lead Resistance Check

Test Procedure:

Measure resistance of each lead between: Pin A and harness connector J2 pin 1. Pin B and harness connector J2 pin 2.

Expected Results:

Measured resistance of each lead is less than 1 ohm.

STEP 12. Check Notch Code Inputs

Test Procedure:

With the Locomotive Control box connected to both connectors (J1 and J2) and the engine running, measure the DC voltage applied by the Locomotive electrical system to the Notch Code Inputs (Connector J1, pins 16, 17, 18 and 19) with respect to the Interface (-) Battery Voltage (at Connector J1, pin 15). Also measure Interface (+) Battery Voltage (at Connector J1, pin 14) with respect to Interface (-) Battery Voltage.

Expected Results:

With "high" inputs (code "1's") defined as being within 8 VDC of the Interface (+) Battery Voltage, and "low" inputs (code "0's") defined as being less than 2 VDC with respect to Interface (-) Battery Voltage, the notch code is constant.

STEP 13. Check for Correct Personality Module

Test Procedure:

Examine the part number on the plate on the Personality Module. Verify that this part number is the correct number for the locomotive system. Verify that system components such as the engine and generator are compatible with this Personality Module part number.

Expected Results:

The Personality Module part number is correct and the system components are compatible with it.

STEP 14. Check for Intermittent Power to Locomotive Control Box

Test Procedure:

Stop engine. Disconnect connector J1 from Locomotive Control box. Measure the DC voltage between harness Connector J1 pins 8 and 9 while the harness leads are manually shaken.

Expected Results:

The battery voltage applied to the Control box is constant and between 64 and 110 volts DC.

STEP 15. Check Diagnostic Lamps on Locomotive Control Box

Test Procedure:

While the engine is running and loaded, observe the diagnostic lamps which are visible at the Locomotive Control box lid.

Expected Results:

GENERATOR LOAD lamp is ON continuously. All other lamps are OFF continuously.

STEP 16. Check for correct adjustment of Voltage and Current Signals

Test Procedure:

Verify proper adjustment of Voltage and Current Signals using Service Procedure G.

Expected Results:

Voltage and Current Signals are in proper adjustment and are not intermittent.

STEP 17. Check Rack Position Sensor Calibration

Test Procedure:

Verify Rack Position Sensor Calibration using Service Procedure D.

Expected Results:

Rack sensor is properly calibrated.

STEP 18. Check GENERATOR LOAD Input

Test Procedure:

With the Locomotive Control box connected to the wiring harnesses and the engine running, measure the DC voltage applied by the locomotive electrical system to the GENERATOR LOAD Input (Connector J1 pin 1) with respect to the Interface (-) Battery Voltage (connector J1 pin 15). Also measure the Interface (+) Battery Voltage (Connector J1 pin 14) with respect to Interface (-) Battery Voltage.

Expected Results:

The DC voltage applied to the GENERATOR LOAD Input is constant and within 8 VDC of the Interface (+) Battery Voltage.

STEP 19. Check WHEEL SLIP Signal

Test Procedure:

With the Locomotive Control box connected to the wiring harnesses and the engine running, measure the DC voltage applied by the locomotive electrical system to the WHEEL SLIP Input (Connector J1 pin 1) with respect to the Interface (-) Battery Voltage (connector J1 pin 15). Also measure the Interface (+) Battery Voltage (Connector J1 pin 14) with respect to Interface (-) Battery Voltage.

Expected Results:

The DC voltage applied to the WHEEL SLIP Input is constant and more than 8 VDC below the Interface (+) Battery Voltage.

STEP 20 Check GENERATOR LOAD Input

Test Procedure:

Expected Results:

The DC voltage applied to the GENERATOR LOAD Input is constant and more than 12 VDC below the Interface (+) Battery Voltage.

STEP 21. Actuator Coil Resistance Check

Test Procedure:

Disconnect wiring connector from actuator. Put a jumper across pins C and D of connector. Measure the actuator coil resistance across connector pins A and B. (See Service Procedure B fig. 2.)

Expected Results:

Measured resistance to be between 30 to 40 ohms.