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1998/02/09 Service Procedures (SENR6430-02)

SMCS - SENR64300007

Introduction
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The information in this section is a supplement to the Checks and Tests of the previous sections. This
material is much more descriptive and detailed for the user who is less familiar with these systems. The

10: 3/04/2 AE6C

Troubleshooting Section makes constant references to this section when more detailed information is
necessary to complete a test.

Service Procedure Index 15

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Procedure A
Wiring Diagram For 8290 Speed Control

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8290 Speed Control

Refer to these notes when using Wiring Diagram for 8290 Speed Control.

Note 1: Shielded wires to be twisted pairs or twisted three conductor, grounded at one end only.

Note 2: No. 12 AWG or No. 14 AWG stranded wire. Must be as short as possible (see maximum length
in "Wire Length Chart").

Note 3: 20 to 32 VDC (7 Amp) continuous.

Note 4: Open for minimum fuel. Do not use either the minimum fuel option, disconnect the actuator
leads or disconnect the power to the control as part of any emergency stop sequence.

Note 5: For positive ground systems, switch and fuse to be located in series with battery (-) and terminal
2. Positive terminal becomes chassis ground. Leads from battery to terminals 1 and 2 must be direct
and not pass through distribution points. Use 10A fuse and switch.

Note 6: Approximate speed change with trim potentiometer:

± 2.5 percent using a 1K ohm potentiometer.

± 5.0 percent using a 2K ohm potentiometer.

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Note 7: Use a 10A fuse (3 AG or GBB type).

Note 8: Polarity not important.

Note 9: Connect control wires only at battery posts, not at other connector points.

Note 10: Approximate one second ramp time per 50 micro Farad. Capacitor specification: 200 micro
Farad maximum, 15 VDC minimum, less than 30 micro Amp DC leakage current over temperature
range.

Procedure B
Linkage Calibration
1. Verify that the levers on actuator and fuel control linkage are the correct length.

Rod End
2. Inspect the rod ends. Rod end replacement should be made when side to side movement of ball (due
to wear) will let ball face become flush with body sides.

3. Install levers to actuator and fuel linkage at the correct angle. Fuel linkage must not bind at any
position in travel range.

4. Make adjustment of linkage to fit levers. Verify that linkage will now move to shutoff and maximum
fuel positions.

NOTE: Rod ends should be adjusted to provide equal thread engagement in both rod ends.

1724 Actuator

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3208 Linkage
(A) Shutoff position. (B) 338.7 mm (13.33 in). (C) 35 ± 5 degrees.

3304 Linkage

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(A) Shutoff position. (B) 412.7 mm (16.25 in). (C) 20 ± 5 degrees. (D) 30 ± 5 degrees. (E) Maximum high idle. (F) Minimum low
idle.

3306 Linkage-Arrangement A
(A) Shutoff position. (B) 268 mm (10.6 in). (C) 35 ± 5 degrees. (D) Maximum high idle. (E) Minimum low idle.

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3306 Linkage-Arrangement B
(A) 10 degrees. (B) 35 degrees. (C) 297 mm (11.7 in). (D) Minimum low idle. (E) Maximum high idle.

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3406 Linkage
(A) Shutoff position. (B) 206.5 mm (8.13 in). (C) 20 ± 5 degrees. (D) 35 ± 5 degrees. (E) Minimum low idle. (F) Maximum high
idle.

524 Actuator

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3304 Linkage
(A) 20 ± 5 degrees. (B) Shutoff position. (C) 30 degrees. (D) Maximum high idle. (E) 358.1 mm (14.10 inches) (F) 52 ± 5
degrees.

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3306 Linkage-XQ Rental Gensets Only

(A) 22 degrees. (B) 30 degrees. (C) 427.0 mm (16.81 inches). (D) Maximum high idle. (E) Minimum low idle.

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3306 Linkage
(A) 75 ± 5 degrees. (B) Shutoff position. (C) 65 ± 5 degrees. (D) 358.1 mm (14.10 in). (E) 30 ± 5 degrees. (F) Maximum high
idle.

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3406 Linkage
(A) Shutoff position. (B) 75 ± 5 degrees. (C) 65 ± 5 degrees. (D) 32 ± 5 degrees. (E) Maximum high idle.

Procedure C
Magnetic Pickup
The magnetic pickup is used to sense engine speed. It is a single-pole, permanent-magnet generator
made up of a coil of wire wound around a permanent magnet pole.

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Schematic Of Magnetic Pickup

When the magnet is placed close to the flywheel ring gear teeth, an AC voltage is generated as the gear
teeth cut through the magnetic field. This output is proportional to engine speed, and is sent to the 8290
Speed Control. The speed sensor in the control box is sensitive only to the frequency of the magnetic
pickup input, so that the amount of the magnetic pickup voltage is important only in that the level is
enough to activate the speed sensor circuits. When connected to the control, about 1 VAC is the
minimum usable level. Voltages up to 50 volts at Rated speed are often generated, depending on the
gap between the gear and magnetic pickup pole piece. This clearance is normally 0.56 to 0.85 mm
(.022 to .033 in).

For field installation, this gap may be set by turning pickup into threads until the magnet is against a
gear tooth while the engine is stopped. Now back pickup out 1/2 turn ± 30 degrees, and tighten locknut
to 70 ± 14 N·m (50 ± 10 lb ft).

Magnetic Pickup Check

Check for more than 1.0 Vrms maximum at Rated speed with magnetic pickup connected to 8290
Speed Control.

Magnetic Pickup Voltage: 1.0 VAC rms minimum, including cranking.

Troubleshooting The Magnetic Pickup

1. Disconnect the pickup leads and check the resistance between these leads (with an ohmmeter) for
150 to 250 ohms.

2. Check between the pickup case and these leads with ohmmeter for almost infinite resistance.

3. Start the engine and control the speed manually, or block the throttle. Check the pickup leads with a
high impedance, AC voltmeter for 10 to 20 volts rms.

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4. Connect the pickup leads again and check at magnetic pickup input terminals T5 and T6 for a
minimum 1.0 volts rms at the lowest controlling speed.

5. If voltage is low, check the clearance between gear and pickup. Inspect the pickup for outside
damage. If defect is found, make a replacement of the magnetic pickup.

Procedure D
Rated Speed Setting
Rated Speed Setting Adjustment
Set Rated Speed potentiometer to Rated speed while external speed trim (if used) is set at center
position.

Remote Speed Trim

For external speed trim, remove the jumper wire from T7 and T8. Connect a 1K ohm potentiometer to
T7 and T8 as shown in wiring diagram (Service Procedure A). This potentiometer gives approximately ±
2.5 percent speed adjustment. External wiring must be shielded, and shield grounded only at the control
end.

Procedure E
Adjust For Stable Operation
A. Adjust for Stable Operation.

8290 Speed Control Functions

1. If engine operation is unstable, go to the following Speed Setting Adjustment procedure.
2. If the engine is hunting at a rapid rate, slowly decrease the GAIN (turn the potentiometer
counterclockwise) until performance is stable. Adjusting the GAIN may cause a momentary speed
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change which can be minimized by turning the GAIN potentiometer slowly.

3. If the engine is hunting at a slow rate, increase the RESET (turn the potentiometer clockwise) until

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the engine stabilizes. If increasing the RESET potentiometer does not stabilize the engine, it also may

202 -0004
be necessary to:
Slowly decrease the GAIN (turn the potentiometer counterclockwise).

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B. Speed Setting Adjustment.
With the engine operating stably, and the external speed trim potentiometer (if used) set at mid-position,

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adjust the RATED SPEED potentiometer to obtain the desired operating speed.

C. Dynamic Adjustment.

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The object of the GAIN and RESET potentiometer adjustment is to obtain the optimum, or desired,
stable speed response due to an engine load change.

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1. Connect a DC analog voltmeter to terminals T3 (+) and T4 (-) to monitor the actuator voltage.

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NOTE: Adjusting the GAIN may cause momentary changes in speed which can be minimized by turning
the GAIN potentiometer slowly. erp
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2. Increasing the setting of the GAIN potentiometer provides a faster transient response because the

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magnitude of the speed change from a sudden change in load is reduced.

To achieve optimum response, slowly increase the GAIN (turn the potentiometer clockwise) until the
voltage on the voltmeter becomes slightly unstable.

Then slowly turn the GAIN back counterclockwise as necessary to stabilize the meter reading.

3. Step-load the generator, or bump the actuator terminal shaft, to make sure the prime mover returns to
the correct speed with little overshoot or undershoot of the speed setting. To reduce overshoot, increase
the RESET (turn the potentiometer clockwise).

4. When the RESET potentiometer is in the lower part of its adjustment (0 to 3 on the potentiometer
scale), increasing the RESET clockwise may require decreasing the GAIN (turning the GAIN
potentiometer counterclockwise) to maintain stable operation.

5. If the engine is slow in returning to the correct speed, decrease the RESET by turning the
potentiometer counterclockwise.

NOTE: Optimum performance is not necessarily obtained with the GAIN potentiometer at the maximum
stable clockwise position. In some cases, the GAIN must be reduced slightly to ensure stability under
widely varying conditions.

NOTE: Field conversion of a three percent Hydramechanical Governor to the 524/1724 Electric
Governor requires a governor spring change to increase droop to 8 to 10 percent.

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Procedure F
Start Fuel Limit Adjustment
NOTE: For applications not requiring start fuel limiting, the START FUEL LIMIT function can be
eliminated by turning the potentiometer fully clockwise.

Set the Start Fuel Limit adjustment potentiometer on units so equipped at mid-position. Attempt to start
the engine. If the actuator moves to a position higher than desired adjust counterclockwise slightly. To
increase the start fuel position turn the potentiometer clockwise. The most ideal setting will be where the
engine starts with a minimum amount of ejected smoke. The Start Fuel Limit will be overridden should
the cranking speed of the engine exceed the selected idle or rated speed.

PSP-0004AE6C
2023/04/23
10:15:25+03:00
SENR64300007
© 2023 Caterpillar Inc.

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