Caterpillar Logic Control Governor One (LCG1) and Caterpillar Logic Control Governor Two (LCG2){1264, 1908} Caterpillar

Industrial Engine:

3054C (S/N: 3341-UP)

Engine:

C3.3 (S/N: E3J1-UP)

Introduction

Reference"General Information"

There are two types of Logic Control Governor, the LCG1 and the LCG2.

The Caterpillar Logic Control Governor is an electronic governor for speed control which contains a rotary actuator. The circuit board for the controller is in the same housing. The unit can provide a number of preset speeds, bias speed and control settings. The unit also provides the link for the diagnostic and the data functions.

This manual covers installation, the programming of software and diagnostics. The functionality of the control unit can be changed with the service tool software.

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NOTICE
Do not perform any procedure that is outlined in this publication until you have read the information and understand the information.

Note: Trained personnel should only carry out installation and servicing. By using proper tools, also correct procedures to carry out the installation.

Function

Functions that set the speed of the governor are listed below.

• Select 50/60 Hz in order to select 1500 rpm or 1800 rpm as the governor speed. This is based on the voltage input when the voltage inputs are applied to the governor.

• 50/60 Hz can increase engine speed.Raise / lower adjust can decrease engine speed. This is based on voltage inputs while the engine is in operation. The functions of the speed bias are listed below.

• The isochronous speed cannot change the speed of the governor. The functions that sense the speed are listed below.

• Magnetic Pick Up (MPU) speed sensing converts flywheel speed or the pulse for the ring gear speed into engine speed, in rpm. Control functions are listed below.

• The coefficients for the speed control are reset, compensation and gain. The logic and support functions are listed below.

• Overspeed error can determine when the actual engine speed is too high.

• Underspeed error can determine when the actual engine speed is too low.

• Fail safe error. Detect engine speed low of the signal input.

• Error on configuration will detect a configuration that has not been downloaded to the controller.

• Relay control controls the driver for the relay output during error conditions.

• Fault storage. Whenever an error has occurred a fault code is recorded. The fault code is recorded as a Electronic Erasable Programmable Read Only Memory (EEPROM) format.

• "Governor state". The generated code by the engine is detected by the governor state: off, crank, start, run, or error. The error is based on code that is generated.

Service Software

The LCG1 and LCG2 have a digital control system with no externally accessible adjustment. Software is available in order to help the dealer or Original Equipment Manufacture OEM with each phase of the application, manufacture and field service. The software for the LCG1 and the LCG2 is compatible with Windows 2000/XP software. The software gives the dealer and the OEM the ability to perform the following procedures:

• Input software files to the LCG1 and the LCG2.

• Enable the technician to view fault codes .

• Enable the Logic control governor software to be updated during the field service.

The logic control governor service tools are available from your Caterpillar dealer.

Refer to Special Instruction, "Caterpillar Logic Control Governor, Software Programming" in order to install the LCG1 and LCG2 software.

Hardware

Hardware is available in the form of kits that meet the specification of the application.

Table 1

Kit number	1	2	3	4
Part number	997-165	997-165	997-168	997-170
Contents	O-ring for the LC governor, Allen head screw, setscrew, and sealing washer	Heat shield, nuts and washers	Magnetic pickup, adapter, 12 pin plug, socket, wedge, connector pins, and blanking plug	Plug, O ring, screw, nut and washer

Note: The following two kits are reusable throughout the range of engines. The kits have the option in order to install the LCG1 and LCG2.

Table 2

Kit number	5	6
After market Part number	997-169	27610278
Contents	Programming harness	CD for programming

System and application

System Operation

When the power supply is connected, the LCG1 and LCG2 are ready to operate within 0.25 second. Power may be connected to the governor. Simultaneously, power to the starting motor is connected. When the engine is started, the engine will immediately select the correct rated speed. The governor will drive the fuel system linkage between the minimum fuel and the maximum in order to maintain a steady speed.

The signal to this solenoid should be sent directly from the engine control panel. The signal should be independent of the governor. When the governor is not powered, the governor cannot drive the actuator to the minimum fuel position.

Note: The LCG1 and LCG2 cannot be used to shut down the engine.

Hardware

The LCG1 and LCG2 has a Deutsch DT04-12PA connector that has 12 pins. This connector is contained in a molded housing. Pins are assigned to specific functions and pins cannot be changed.

The table below shows the assignments to each auxiliary based function in the control.

Table 3

Function	Aux 1	Aux 2	Aux 3	Aux 4
Isochronous	X
50/60 Hz select				X
Lower speed		X
Raise speed			X

50 / 60 Hz

This feature allows the engine speed to be set. Between the primary rated engine speed and the secondary engine rated speed, a discrete input is used to toggle between the two set speeds. The input comes into AUX4. When the engine is started with the input at the low state (ground), the controller will adjust the engine speed to the" 50Hz" speed setting. When the engine is started with pin in the high state +12V dc, the controller will run at the "60Hz" speed setting. Any change on AUX pin will be ignored once the engine is running. The state is determined only when power is first applied to the governor.

Raise and Lower engine speed

This feature allows the user to change the engine speed with external voltage inputs. Speed will change at the rate of two rpm second.

Note: This must not be used for ramping from 50 Hz to 60 Hz.

Lower

This AUX2 voltage input acts directly on the internal engine speed within the LCG1 and the LCG2. This decreases the speed of the engine progressively to a lower limit. The speed will change at a rate of two rpm per second as long as the input stays in the high state. The input can change from a high state to a low state. The reference point for the speed will remain fixed at the last setting that is reached. The input will revert to a low state.

Raise

This AUX3 voltage input acts directly on the internal speed within the LCG1 and the LCG2. This increases the speed of the engine progressively to a upper limit. The speed will change at a rate of two rpm second as long as the input stay in the high state. The input will revert to a low state. The reference point for the speed will remain fixed at the last setting that is reached. The input will revert to a low state.

Speed Biasing

Isochronous

This is the default speed biasing function that maintains the engine at one speed setting throughout operation regardless of load.

Auxiliary Biasing (Isochronous load sharing)

This feature allows the user to alter the set point for the auxiliary biasing (isochronous load sharing) with an external signal. The auxiliary biasing (isochronous load sharing) files can be altered by using the appropriate software and a load sharing unit. This input signal connects into AUX1. The input signal is a programmable ±3V input. This function modifies the desired engine speed with the following formula:

• Speed reference x bias percentage x offset AUX1 input voltage

The bias percentage is a programmed value of ± 7%. This analog input should be provided by a voltage transmitter via twisted, shielded wire pairs.

Speed Sensing

Magnetic Pickup

The MPU input has been designed for a variable reluctance speed sensor. The frequency range of the MPU input 100 Hz to 12 Hz. The MPU input will accept at least 14 Hz in order to provide a margin of safety. The required minimum peak to peak voltage is 12 volts at 100 Hz and 25 volts at 12 Hz.

A voltage of ± 3V is required from the MPU on pin 11. The number of flywheel or gear teeth that pass the magnetic pickup for one crankshaft rotation is programmed into the configuration file. The Caterpillar configuration files will allow 126 gear teeth per revolution.

To calibrate the Caterpillar MPU input, the crankshaft must be rotated 360 degrees. Position the flywheel at the highest point that is adjacent to the MPU aperture. The dial test indicator (DTI) is required for the procedure. Screw in the MPU until the face comes into contact with a tooth for the starter ring gear. Then unscrew by half to one turn in order to give a gap of 0.5 ± 1.0 mm (0.0198 ± 0.039 inch). Tighten the locknut. Rotate the crankshaft. Ensure that there is no contact between MPU and the tooth of the ring gear.

Related configuration files are MPU and flywheel teeth.

Control Functions

Speed Control

This is the function of the governor. The speed control calculates the difference between the desired speed and the actual measured engine speed. The speed control will adjust the desired actuator position. The functions that set the speed are responsible for selecting the set point for the active speed. Dynamic functions set the dynamics for this function.

Dynamics Functions

A variety of dynamics or gains are available for tuning the engine and the response of the actuator. The response of the movement of the actuator is controlled by Proportional Integral And Derivative (PID) control. The speed control of the engine is controlled by the following functions.

• Reset

• Gain

• Compensation

The user has access to these terms.

Dual Dynamics

The feature allows the user to toggle between two sets of user defined dynamics or gains. The dual dynamics are not enabled on Caterpillar configuration files.

Timing for Cold Start

Gensets that require G3 performance are also susceptible of an unstable cold start. The LCG1 and LCG2 is equipped with a timer for a cold start. The timer will set the gain of the controller to a lower value until the time expires. This gives an engine time in order to warm up before switching to a normal gain value.

Automatic Gain Trim

The LCG1 and LCG2 contain a function in order to adjust the automatic gain. The function will correct the variations in engine power. The variations in engine power will affect the performance of the governor. The function adjusts the gain of the controller which is based on a steady state measurement and transient engine speed measurement. The LCG1 and LCG2 is programmed for the stability of the engine. The function is used to compensate for the effects of the following:

• Altitude

• Temperature

• Fuel quality

The function that is programmed into the LCG1 and the LCG2 is not intended to compensate for serious engine faults.

This function continuously monitors the speed of the engine relative to the currently active reference engine speed. If this function observes a steady state speed band that exceeds a programmable set point then the currently active gain is decreased until the programmable minimum gain setting is reached. When this function detects a transient off speed change that exceeds the currently active set point, the gain is increased until the set point is achieved. The currently active parameter is increased until the programmable maximum gain setting is reached. This feature is not adjustable.

Logic And Supporting Function

Engine Overspeed

The LCG1 and LCG2 control has an overspeed function. This is set to shut down the engine at 2080 rpm. The function of the engine overspeed is typically 110% of the maximum rated engine speed. Detection of engine overspeed is a function of the LCG1 and LCG2. The actuator on the LCG1 and the LCG2 will be driven to the minimum fuel. This will activate the relay output, and the software will store a fault code in EEPROM. Cycling power to the LCG1 and the LCG2 will restore normal operation, but the fault will remain in non-volatile memory until this is reset.

Note: The LCG1 and LCG2 control is not used as the primary device for overspeed protection.

Related configuration File

• Overspeed

• EEPROM store a fault code.

• Relay control

• Overspeed function

Underspeed Error

The LCG1 and LCG2 has a programmable underspeed function that is set to shut down the engine at 480 rpm. Detection of engine underspeed is a function on the LCG1 and the LCG2. The actuator on the LCG1 and the LCG2 will be driven to the minimum fuel. This will activate the relay output, and the software will store a fault code in EEPROM.

Fail safe Error

Protection of the engine against overspeed upon loss of the speed input signal. Detection on overspeed upon the loss of speed input signal the function of the actuator on the LCG1 and the LCG2. The LCG1 and LCG2 will drive the actuator to the minimum position. Loss of engine speed output from the MPU that exceed the programmed 0.5 second. The relay output will also be turned "ON" and the software will store a fault code in the EEPROM. Cycling the power to the LCG1 and the LCG2 will restore normal operation. The fault code will remain in non-volatile memory until the non-volatile memory is reset.

Related Parameters for the Configuration File

• Failsafe.

• Fail Safe Timeout Period.

• EEPROM Fault Storage.

• Relay Control.

Configuration Error code

The error codes for the LCG1 and the LCG2 are permanently enabled. The software for the governor will check for error codes.

If a configuration error code is detected the system will shut down. The error code must be cleared. Re activated the system.

Relay Control

The discrete output is a closure to ground. The discrete output is capable of sinking 250mA. 1.5V is available to power external relays for devices such as fuel shutoff solenoids. the LCG1 and LCG2 has a diode for protection, so it is not necessary to provide one externally. This output is normally floating with a very weak resistor. The LCG1 and LCG2 has a +ve 5V internal voltage.

The following codes are listed.

• Overspeed

• Configuration

• Failsafe

This output sinks up to 250mA to ground "-".

There are two conditions that well prevent this output from operating:

• The connection of the battery"+" lead.

• The connection of the lead to ground "-"

If this output is intended to drive a fault light, these conditions will not be obvious.

Storage of Faults

Detection of an error code by the LCG1 and the LCG2 is then stored in the EEPROM. The following codes are listed.

• Configuration

• Overspeed

• Failsafe

Preliminary Adjustments

This section covers the installation of the LCG1 and the LCG2 to the fuel pump and to the associated electrical system.

Setting Instructions for Droop screw

Note: Disconnect the power supply before working on the fuel injection pump.

1. Clean the upper surface of the fuel injection pump in order to remove dirt.

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Illustration 1	g01238425
Droop setting screw

2. Release the locknut (1) on the droop setting screw (2). Turn droop setting screw (2) clockwise until droop setting screw lightly contacts with the fuel metering valve. Refer to illustration 1.

3. Adjust the droop setting screw (2) in a counter clockwise. The number of turns are specified in table 4. Tighten the locking nut (1) to 4.5 N·m (39.8 lb in). Do not exceed this torque.

   Note: Excessive tightening of the droop setting screw will cause damage to the metering valve.

Setting Frequency with No Load Applied

Note: When generator sets have a overspeed protection system this should be set to 65Hz or 1950 rpm.

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Illustration 2	g01236928
Speed setting

1. Run the engine with no load. Release the locknut on the screw on the throttle lever (3). Also release the locknut on throttle lever (4). Lightly tighten only the locknut on the throttle lever. (3). Then adjust the throttle screw (5) in order to set the frequency to the limits. Set the frequency that is specified in the tables. Refer to table 4 for the specified frequency. Tighten the locknut on the throttle lever (3). Tighten the locknut on the throttle lever (4) to 5.7 N·m (50 lb in). Refer to illustration 2.

Setting Frequency With Full Load Applied

1. Running the engine with full load applied. Refer to ""Setting Instructions for Droop screw" ". Adjust the droop setting screw until the frequency is within specified limits. Refer to table 4 for specified limits.

Table 4

Current models (Tier Zero - 2)
Setting the generator Frequency
Engine models	Curve	"50 Hz"		"60 Hz"		Adjustment of droop screw. The number turns from the counter clockwise.
-		Full Load (Hz)	No Load (Hz)	Full Load (Hz)	No Load (Hz)	-
C3.3	T2450	N/A	N/A	60	62.2 ± 0.6	No application
3054C	T2442	N/A	N/A	60	62.2 ± 0.6	No application
3054C	T2428	N/A	N/A	60	62.2 ± 0.6	No application
3054C	T2460	N/A	N/A	60	62.2 ± 0.6	No application

Setting Frequency at No Load

Note: When generator sets have a overspeed protection system this should be set to 65Hz or above.

Illustration 3	g01236928
Speed setting

1. Run the engine with no load. Release the locknut on the screw on the throttle lever (3). Also release the locknut on throttle lever (4). Lightly tighten only the locknut on the throttle lever. (3). Then adjust the throttle screw (5) in order to set the frequency to the limits. Set the frequency that is specified in the tables. Refer to table 4 for specified frequency. Tighten the locknut on the throttle lever (3). Tighten the locknut on the throttle lever (4) to 5.7 N·m (50 lb in). Refer to illustration 3.

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Illustration 4	g01238425
The setting screw for the droop

2. Release the locknut (1) on the droop setting screw (2). Turn clockwise droop setting screw contacts with the fuel metering valve lightly. Refer to illustration 4.

3. Adjust the droop setting screw (2) in a counter clockwise. The number of turns are specified reference to table 4. Tighten the locking nut (1) to 4.5 N·m (39.8 lb in). Do not exceed this torque.

   Note: Excessive tightening of the droop setting screw will cause damage to the metering valve.

4. This should be adequate adjustment, if full load cannot be achieved. Adjust the droop setting screw in a counter clockwise. Adjust the droop setting screw by one flat and then tighten.

5. If the performance is unstable, then adjust the droop setting screw clockwise by one flat of the screw and tighten the locknut. If instability is still present then repeat this step. Check that full load can be achieved.

   Note: The mechanical engine governor over speed should be set.

6. Release the locknut on throttle lever (3) and the locknut on throttle lever (4). Lightly tighten only the locknut on the throttle lever (3). Then adjust the throttle screw (5) in order to set the frequency. Tighten the adjustment screw locknut (4) and the locknut on the throttle lever (3) to 5.7 N·m (50 lb in). Refer to illustration 3.

7. The LCG1 and LCG2 can now be installed.

Installation of Caterpillar LCG1and LCG2

Note: In order to install the LCG1 and LCG2 to some engines, remove the fuel injection pump prior to installing the LCG1 and LCG2. Refer to table 5 for the correct publication and the correct procedure.

Table 5

Engine models	Publication reference
C3.3	KENR6212
3054C	RENR2433

Illustration 5	g01249051
Typical example

A modified cylinder head has been introduced. This cylinder head allows installation of the LCG1 and the LCG2 (1) without removal of the fuel injection pump. The following engines are installed with the latest modified cylinder head (2).

Illustration 6	g01240539
Blanking plugs and threaded holes

1. Ensure that the engine is stopped. Isolate electrical supply. Remove the protective cover (not shown). Ensure that the threaded holes (3) are free from debris.

   Note: Ensure that the fuel supply is turned off.

2. Ensure that the area around the plug (4) is clean. Use a suitable tool to remove the threaded plug (4). Ensure that the seal remains attached to the plug. Retain the plug and seal. Ensure that the threads in the body (3) are not damaged. Refer to illustration 6.

   Note: Ensure that no debris enters the pump.

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Illustration 7	g01240624
Installation of LCG1 and the LCG2 to fuel injector pump

3. The O-ring of the LCG1 and the LCG2 governor (5) should be lubricated with clean diesel fuel. The actuator lever (6) on the LCG1 and the LCG2 governor. The lever on the governor (6) should be rotated to the fully clockwise position. The governor (7) should be then installed. Then install the governor to the fuel injection pump. The governor should be aligned to the injection pump. Then install the fixing. The actuator lever (6) is positioned to the right of the fuel control linkage (8). Refer to illustration 7.

   Note: Ensure that the governor is aligned correctly into the pump body. Incorrect alignment may cause serious damage to the generator if there is no overspeed protection.

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Illustration 8	g01240643

4. Push the governor (7) fully into the position and then tighten the four setscrews (9) to 4 N·m (35.4 lb in).

   Note: The governor should fit easily into the pump. If the governor does not fit easily, do not use force. Remove the governor and check that the actuator lever (6) is correctly aligned to the fuel control linkage. Refer to the illustration 7.

5. Connect the electrical connector (10) .

6. The LCG1 and LCG2 may now be programmed by using the LCG1 and the LCG2 software.

Note: If it is necessary to remove the fuel injection pump, then the LCG1 and LCG2 should not be removed from the injection pump in order to prevent any dirt from entering the injection pump.

Electrical Installation

Plug for the LCG1

Illustration 9	g01245553
The configuration of the pins on Type 1 Plug for LCG1 (1) 12V (2) GND (3) MPU - ve (4) AUX3 (Raise speed) (5) AUX1 - ve (GND) (load sharing) (6) AUX4 (60Hz select) (7) AUX1 + ve (Load sharing) (8) Error Relay (9) AUX2 (lower speed) (10) MPU + ve

Note: If any of the features are not required in the application the related wiring may be omitted.

The LCG1 has a operating voltage of 8 to 12volt dc with a nominal voltage of 13.5 volt dc. The power supply is load dump and reverse polarity protected. This consumes 64 watt maximum power at a peak current of 4 amps. This is at 16 volt dc with a 4 ohm resistance at temperature 25 °C (77 °F). The control system should be protected with a 6 amp fuse in the power supply line. The application should be configured to turn on power to the governor when the engine is first switched to the starting position. The power should be removed just before the engine is shut off. This allows the actuator to deactivate.

Plug for LCG2

Illustration 10	g01245955
The configuration of the pins on Type Two Plug for LCG2 (11) 12/24V (12) Aux1 MPU - ve (13) Aux2 + 12V to lower speed (14) GND (15) Aux4 1800 RPM (60Hz) NOTE: Speed changes cannot be made when the engine is running. The speed setting must be made before power supply to pins (1) and (14). (16) Aux1 Load Sharing (17) Aux3 Raise speed (18) MPU + ve

The LCG2 has an operating voltage of 10Volts to 32volt.

Programming Harness for LCG1

Wiring Diagram for LCG1 programming harness

Illustration 11	g01246521
Wiring harness diagram for LCG1

Table 6

LCG1
Key	Description
19	Speed sensor
20	12 Pin in a connector
21	On/Off switch in programming harness
22	Connection for hooking up a computer

Wiring Diagram for LCG2

Illustration 12	g01246523
The wiring harness diagram of LCG2

Illustration 13	g01271747

Wiring Diagram for LCG1

Illustration 14	g01271747
The diagram for the wiring harness of LC 1 governor

Note: Speed changes on the 1800 rpm cannot be made when the engine is running. The speed setting must be made before supplying power to pins one and five.

Setting of Speed Sensor

Illustration 15	g01247025
Curve for MPU voltage

MPU input voltage is the requirement versus input frequency.

The LCG1 and LCG2 has an output driver that activates the relay. The relay is activated at any time when an error is detected by the LCG1 and LCG2.

• Overspeed

• Underspeed

• Fail safe

• Configuration error

The driver can sink up to 250mA of current. This is through an external device that is powered with a + ve voltage. The driver internally protected against inductive back feed.

The LCG1 and LCG2 have three dedicated digital inputs. AUX2 AUX3 AUX4 The inputs are used in order to activate various features of the control. Shorting out of a input pin to +ve 12 Volts dc activates. Removal of +ve 12Volts dc from the input pin or shorting the pin to ground deactivates the input. At least 4Volts dc must be present on an input pin in order to changes. This changes the inactive state to a active state. All discrete inputs will be the same voltage as the supply to the power for the system. This activates only while the input is in a high state. Voltage that is greater than 4 Volts dc is high. Voltage that is less than 1 Volt dc is low.

The pins on the connector are protected from shorting to ground and to the power supply. This is except pins 2,3 and 5. These pins are not protected against shorting to the positive side of the electrical system. installing of a fuse on number two pin would provide protection to these pins. Installation of a fuse on pin 1 is still required on the connection. Pin 1 B+ve still needs protection against a short to grounds.

AUX1 is configured as a ±3Volts dc analog input. LCG1 and LCG2 can be interfaced to other electrical equipment through the AUX1 +ve and AUX1 -ve inputs Isochronous load sharing.

Table 7

-	Recommended	Optional
Mating connector	DT06-12SA-P012	DT06-12SA
Secondary lock	W12S-P012	N/A
Socket	0462-201-16141	0462-201-16141

The above Deutsch components are recommended for designs of the harness.

Use 1-1.5 mm2 16 to 18 AWG stranded copper wire with insulation that meets temperature that is the requirements in the design of the harness. Wires on the connector that are not used should be installed with a blank plug Deutsch 114017. Seal the connector from the elements of the environment. The wire harness within 400 mm (16 inch) of the connector is recommended. The maximum recommended harness length is 6.1 m (20 ft). The wiring harness should be a single bundle. Use grommets when the harness is passed through metal panels. Ground the shielded wire of the MPU signal wire at the controller on the LCG2. Ground the wire at the setscrew on the body of the governor. Do not ground the shielded MPU signal wire at the MPU.

The shielded wire for the AUX1 input should be connected together when Isochronus Load Sharing is used. Ground this shield on the engine near the control.

Software for Programming

This section covers the process to programming with software.

• Tune the configuration files.

• Service the LCG1.

Listed hardware is required to carry out adjustment to the LCG1. The application is being developed by engineering. A configuration file is being downloaded in production or the application is being serviced in the field.

• PC compatible laptop computer or work area with a computer at least one available serial port communication port and Windows 2000 XP as the operating system

• Programming with a data link harness for programming

Programming and Running Connections

Illustration 16	g01304977
Connection for LCG1 and LCG2

Software Installation

Note: Trained personnel should only carry out installation and servicing. By using proper tools, also correct procedures to carry out the installation.

The software is available on CD. After the loading of the software has been carried out the computer will be need to be restarted in order to update the registry.

Programming Screen for LCG 2

Illustration 17	g01248436
View of LCG 2 screen

Illustration 18	g01248447
The view on this screen shows that no power is present at the LCG 2.

This section is on loading the configuration file to the LCG 2.

Illustration 19	g01248464
Open configuration file for LCG 2.

Illustration 20	g01248466
Selection of the correct file for the LCG 2 from the menu on the screen

The password can be supplied by the Caterpillar dealer.

Illustration 21	g01248472
Enter the password. Select the OK option for the LCG 2.

Illustration 22	g01248475
Files of the configuration over view for LCG 2

Illustration 23	g01248478
The file of the configuration has been completed. Then load the file to the LCG 2.

Illustration 24	g01248483
Enter the password. Select the OK option or the LCG 2.

Illustration 25	g01248487
Wait for the loading configuration file to the LCG 2.

Checking the configuration file in the LCG 2

Illustration 26	g01248494
Open Control of the Configuration for LCG 2

Illustration 27	g01248499
Enter the password. Then select the OK option for LCG 2.

Illustration 28	g01248507
Files of the configuration over view for LCG 2

Change the set point. Method 1 is via the Edit Speed Dynamics.

• Proportional integral

• Derivative

Illustration 29	g01248513
Tools Selection for LCG 2

Illustration 30	g01248526
Edit Speed Dynamics for LCG 2.

Illustration 31	g01248532
Dynamics 1 overview for LCG 2

Illustration 32	g01248535
Saving setting for LCG 2

Change the set point. Method 2 is via Edit position Proportional Integral Derivative (PID).

Illustration 33	g01249048
These gains are the only gains that need to be changed for the LCG 2.

Illustration 34	g01248551
Selection of Tools for LCG 2

Illustration 35	g01248559
Open the menu for tools. Open the menu for Edit Position PID for LCG 2.

Illustration 36	g01248574
Enter the password. Then select the OK option for LCG 2.

Illustration 37	g01248588
PID selection and real time monitoring for LCG 2

Illustration 38	g01248595
Saving PID setting after adjustment for LCG 2

Diagnostics

General Troubleshooting Guide for the System

The following is a general troubleshooting guide for the area in order to be checked. Make these checks appropriate to your engine before contacting your Caterpillar dealer for technical assistance with your system problems. These checks will ensure that the fault can be more accurately assessed.

• Carry out the checks on the wiring.

• Check the direction of the actuator.

• Check the working direction of shutdown of the failsafe.

• Check the smooth operation of the fuel metering valve.

• Check the fuel metering valve for full travel.

• Check the middle position of the metering valve. This can be achieved and held.

• Carry out the checks on the wiring.

• Check the direction of the actuator.

• Check the working direction of shutdown of the failsafe.

• Check the smooth operation of the fuel metering valve.

• Check the fuel metering valve for full travel.

• Check the middle position of the metering valve. This can be achieved and held.

The Engine Does Not Start.

Possible causes

• Stuck throttle and frozen shaft

• Power not applied to control.

• The engine run is not closed.

• Incorrect configuration in control

• Detected fault in the control

• MPU gap is too large.

• MPU signal.

• MPU connections

• The signal from the ignition

• The connection on the ignition

• Wrong configuration file

Recommended Action

1. Move the throttle by hand.

2. Assess smoothness.

3. Disconnect the solenoid from the starter.

4. Disconnect the harness from the governor.

5. Test for + 12/24V between + 12/24V pin and ground for the LC 2 Governor. Test for 2V RMS between MPU + pin and MPU - pin for the LC 1 Governor.

6. Verify status of input. Measure input.

7. Check the input with the electronic service tool.

8. Configuration use the electronic service tool.

9. By using the electronic service tool, read configuration from control and evaluate the parameter for the correction.

10. By using the electronic service tool, read faults from control.

11. Verify and correct any shutdown conditions.

12. Remove MPU per OEMs instructions. Install the MPU per OEM instruction.

13. Rotate the engine manually to the check for interference.

14. Disconnect the harness from the governor.

15. Test for at least 1 V RMS between MPU + pin and MPU - pin while the flywheel is turning.

16. Disconnect the harness from the governor.

17. Crank the engine. As the engine is cranked, test for the voltage fluctuation. Check the voltage between pins one and two on the LCG1. Refer to the illustration 11 for pin numbers and the position. On the LCG2, check the voltage between the pins one and two. Refer to illustration 12.

Engine Starts, but the Engine Shuts Down (LCG 1)

Possible causes

• MPU gap is too large.

• MPU signal is intermittent.

Recommended Action

1. Remove MPU per OEMs instructions. Install the MPU per OEM instruction.

2. Rotate the engine manually to the check for interference.

3. Disconnect the harness from the governor.

4. Check the resistance between the MPU + pin and MPU - pin. Inspect the harness and the connections.

Incorrect Mode of Operation (LCG 1)

Possible causes

• The AUX inputs are shorted or open.

• There is a problem with the linkage.

Recommended Action

1. Disconnect the starting motor solenoid.

2. Disconnect the harness from the governor.

3. Activate the application.

4. Check for the correct voltage between the AUX pins and the ground floor for known modes of application.

5. Move the linkage by hand.

6. Check for smoothness, friction and the spring force.

Unable to Develop Full Power (LCG 1)

Possible causes

• Wrong configuration file

• Seized shaft

• Set the fault code.

Recommended Action

1. Disconnect the harness from the governor.

2. Attach the programming harness.

3. View status of the fault codes.

4. Take appropriate action for active faults.

Engine Runs but Speed Increases or the Speed Decreases (LCG 1)

Possible causes

• The programming harness is still connected to the computer.

• A voltage is being applied to pin 4 or pin 10.

Recommended Action

1. Restart the configuration file and disconnect the computer.

2. Reset the speed.

3. Remove the voltage supply to pin 4 or pin 10.

Overspeed Error (LCG 1)

Possible causes

• The gains are not set for the transients.

• Wrong configuration file

• Speed sensing error.

Recommended Action

1. Raise the common gain in order to reduce overshoot.

2. Follow the instructions for the MPU intermittent under Failsafe Error.

Failsafe Error (LCG 1)

Possible causes

• MPU signal intermittent.

• The engine runs at very low speed.

Recommended Action

1. Disconnect the harness from the governor.

2. Check continuity between IGN pin and the primary ignition coil. Inspect the harness and connections while the engine is cranked.

3. Increase the failsafe timeout period.

Configuration Error (LCG 1)

Possible causes

• A configuration file has not been written to the controller.

Recommended Action

1. Disconnect the harness from the governor.

2. Attach the programming harness to the governor.

3. Write the configuration file to the controller. Use the software tools.

The Actuator Is Not Opening The Fuel Control Valve During Engine Cranking.

Possible causes

• The control is configured for the correct direction of opening.

• The input to the The Run Enabled has not been enabled.

• The control has detected a shutdown fault. The fault must be reset.

• No power supply at the control

• The control does not read any speed.

• The speed sensor is faulty. Wiring defect to the sensor or incorrect sensor installation

• The control reads an actual engine speed below the Start Speed Threshold.

• The Start Fuel 1 and 2 setup is incorrectly set.

Recommended Action

1. Check the configuration of the clockwise minimum fuel. Check the configuration of the minimum fuel in the counter clockwise.

2. Make sure that The Run Enable input is made active.

3. Check the wiring.

4. See the overview screen on the service tool.

5. The reset of the controller by cycling power to the control, or hitting reset on the Service Tool. The reset can be carried out by toggling of the switch for The Run Enable.

6. Check the fuse, wiring, and battery voltage.

7. Replace the speed sensor. Repair wiring or install a new sensor correctly according to the instruction of the sensor.

8. The set point of the engine starting speed is set too high.

9. Lower start Speed Threshold.

10. Set the Start Fuel to the correct value for this engine.

The Engine Speed on Start-up Goes to Overspeed

Possible causes

• An overshoot in speed is caused by an excessive Speed Setpoint Acceleration.

• The Overspeed Trip Level is configured incorrectly.

• Incorrect speed input of the configuration

• Gain for the speed value is not set correctly for transients.

• Start Fuel Limit is not set correctly.

• Sensing the speed error

• Wrong configuration file

Recommended Action

1. Acceleration Ramp Rate is too high a setting.

2. Verify the Overspeed Trip setting of the configuration.

3. Verify the Input Speed Configuration setting (Number of Teeth).

4. Check the sensed speed.

5. Compare this speed to an external engine speed indicator.

6. When overspeed occurs on the transient raise common gain. This will reduce the overshoot.

7. Lower rpm Run Threshold or lower start of the fuel position.

8. Follow the instruction for the MPU speed error.

9. The signal from the ignition is intermittent under Speed Sensor Error.

Check the power to the LC 1 Governor. Check the linkage on the shaft.

Operation Of The Speed Is IncorrectSpeed Baise The Function and the Dynamics

Possible causes

• AUX input shorted.

• The circuit on the AUX may be the open.

Recommended Action

1. Disconnect the solenoid from the starting motor.

2. Disconnect the harness from the governor.

3. Check for correct voltage level at the pin for the known modes for the application

The Engine Will Not Go To Idle Speed.

Possible causes

• The idle rated input wiring is faulty.

• See the overview screen for the input position.

• The selection for the high also low idle is incorrect.

• The active open or closed selection for the idle, rated input is selected incorrectly.

• The control is not configured for idle rated operation.

Recommended Action

1. Check wiring.

2. Set up the correct input modes.

3. Configure the Control for Idle rated operation if this is the correct operation mode.

The Engine Will Not Raise to the Setpoint for the Selected Speed.

Possible causes

• The Raise Input wiring is faulty.

• The selection for the high also lowraise is incorrect.

• The active open or closed selection for the Raise Input is selected incorrectly.

• The control is not configured for Raise Lower Operation.

• The Lower input is also active and the Analog Raise Lower is configured.

• The Lower is active and only Raise Lower is selected.

• The control will lower the speed if the Raise and the Lower are selected at the same time.

Recommended Action

1. See the overview screen for the input position.

2. Check wiring.

3. Set up the correct input modes.

4. Configure the control for Raise Lower Operation.

5. Raise Lower and Analog for the setpoint of the speed for the operation of the mode

6. Set up the lower input to the correct state.

7. The engine will not lower the Speed Setpoint.

8. Set up the lower input to the correct state.

9. The engine will not lower the setpoint for the speed.

The Engine Will Not Lower From the Setpoint for the Speed.

Possible causes

• The Lower input wiring is faulty.

• The High / Low or the active open or the closed selection for the idle Raise Input is selected incorrectly.

• The control is not configured for Raise Lower Operation.

• The Raise Input is also active.

• The mode for the analog is active.

Recommended Action

1. See the overview screen for the input position.

2. Check wiring.

3. Set up the correct input modes.

4. Configure the control for Raise Lower Operation.

5. Raise Lower and Analog for the setpoint of the speed for the operation of the mode

6. Set the lower input to the correct state.

7. The engine will not lower the Speed Setpoint.

The Engine is Unstable.

Possible causes

• Improperly tuned speed or position PID dynamics.

• Intermittent signal of the speed or incorrect signal of the speed

• Dual Dynamics discrete input shorted or open.

Recommended Action

1. By using the electronic service tool, tune the position of the dynamics.

2. Most of the default dynamics are appropriate.

3. By using the electronic service tool, tune the dynamics of the speed.

4. Verify the Speed signal shielding .

5. Check the recommendation in the ""Setting Of Speed Sensor" ".

6. Verify that the speed input is wired correctly.

7. Ignition and MPU cannot be wired simultaneously.

8. Disconnect the solenoid for the starting motor. Activate the application.

9. Check the correct voltage level between dual dynamics AUX. Pin for the known application required mode.

Poor Frequency Control

Possible causes

• Improperly tuned dynamics

• The friction is improperly set.

Recommended Action

1. Use the electronic service tool to tune the dynamics of speed control.

2. Use the electronic service tool to tune the position of the dynamics.

3. Default dynamics in most cases are appropriate.

4. Use the electronic service tool to adjust the setting of the friction.

Unable to Develop Full Power

Possible causes

• The linkage (6) has slipped on the shaft. Refer to illustration 7.

• A Fault is detected in the control. Refer to illustration 7 (7) .

• Shorted MAP sensor signal or poor connection

Recommended Action

1. Manually verify full travel of throttle plate.

2. Use the electronic service tool to view status of the fault code.

3. Take appropriate action for the active faults.

4. The connection on the MAP fuel limiting has become disconnected from the solenoid of the starting motor.

5. Verify the input voltage that matches expected voltage. Expected for the atmospheric condition

Discrete Output is Not Working

Possible causes

• Wiring fault

• Configuration

Recommended Action

1. Check the wiring to pin 9 for open connections. The connection is correctly connected to pin 9.

2. Verify that pin 9 is connected directly to input power or ground.

3. Use the electronic service tool to check that the faults and shutdown are selected and that the output is configured. The normally expected operation "ON" or "OFF"

The Service Tool Is Not Communicating Not Connected Status Indicated

Possible causes

• Wiring fault

• The electronic service tool is disconnected.

• The incorrect communication port has been selected.

Recommended Action

1. Check AUX3 and AUX4 for the loose connection. The connection not correctly connected.

2. Verify the setup of the harness and the connection.

3. Check the running of the electronic service tool.

4. Verify the correct port setting.

5. Check fuses, wiring, and battery voltage.

6. Connect the electronic service tool by using the menu.

The electronic service tool Is Not Communicating Error Message Displayed

Possible causes

• The old version of electronic service tool or the file is corrupted.

Recommended Action

1. Reinstall the electronic service tool in order to get the latest version from your Caterpillar dealer.

Service Tool will not accept password.

Recommended Action

1. The Password is case sensitive. Ensure that the password is entered correctly.

2. If the password is lost contact a Caterpillar dealer for retrieval.

• The keyboard Caps Lock is on.

Programming diagnostics (LC 1 Governor)

Error message: Missing ACCESS.KEY file

Possible causes

• The configuration file has an OEM security key.

Recommended Action

1. Obtain the correct configuration file.

Error message: The configuration data is the wrong format. Try converting the data to the current LC governor Firmware Rev

Possible causes

• The configuration file is not the same version as the actuator.

Recommended Action

1. Obtain the correct configuration file.

Error message: Timed out

Possible causes

• No power to the actuator

Recommended Action

1. Check the connections and retry.

Error message: Unable to establish link. Exit real time tuner?

Possible causes

• No power to the actuator

Recommended Action

1. Check the connections and retry.

Control Specifications LCG 1

Specification and Characteristics

Specifications

Power Supply ... 12 Volts 8 - 16VDC Reverse polarity protection

Power consumption ... 64 Watt maximum

Nominal Torque ... 0.34 N·m (0.25 lb ft)

Mass ... 0.425 kg (0.93 lb)

Control Characteristics

Speed input and range ... Magnetic pickup 126 teeth per rev

Engine type ... 4 cycle diesel fuel

Target speed ... 50 Hz/60 Hz

Torque for the actuator ... 0.34 N·m (3 lb in)

Function speed ... Isochronous speed 50 Hz or 60 Hz

Environment

Ambient

Operating temperature ... −40° to 85°C (−40 ° to 185 °F)

Storage temperature ... −40° to 125°C (−40 ° ± 257 °F)

EMI/RFI ... EN50082-1 emissions for industrial environments

EMI/RFI ... EN50082-2 immunity for industrial environments

Humidity ... US MIL-STD 810E method 507.3 Procedure three

Spray of Salt ... US MIL-STD 810E method 509.3 Procedure one

Shock ... US MIL-STD 810E method 516.4 Procedure one

Random Vibration ... US MIL-STD 202F Procedure 214A Test Condition ID

Drop ... SAE J1211, Paragraph 4.8.3 (modified)

Thermal shock ... SAE J1455, Paragraph 4.1.3.2

Dust ... SAE J1455, Paragraph 4.7

Pressure wash ... SAE J1455, Paragraph 4.5 (modified)

Fluid resistance ... SAE J1455, Paragraph 4.4 (modified)

Electrical Load, Power, Connection Electrical Transient ... 2 J per SAE J1455, Paragraph 4.11.2.2.1

Control Specifications LCG 2

Specification and Characteristics

Specifications

Power Supply ... 12/24 Volts 10 - 32VDC Reverse polarity protection of 2.5 Amp max

Power consumption ... 32 Watt maximum

Nominal Torque ... 0.34 N·m (0.25 lb ft)

Minimum Transient Torque up to 105°C ... 0.28 N·m (0.20 lb ft)

Continuous Minimum torque up to 105°C ... 0.20 N·m (0.15 lb ft)

Mass ... 0.425 kg (0.93 lb)

Power up to operation time ... <250 milliseconds or <1 second CAN version

Performance

Accuracy of the speed control ... MPU input ± 0.25% of rated speed. 126 teeth per revolution

Transient behavior ... Diesel <10% at 100% dissipation of the load <-7% at 100% load recovery.

Recovery time ... 3 seconds

Environment

Ambient

Operating temperature ... -40°C to +105°C

Storage temperature ... -40°C to +125°C

ENC ... EN61000-6-2 immunity for industrial environments

ENC ... EN61000-6-4 emissions for industrial environments

ENC ... SAE J1113-21 Radiated immunity (100V/m)

ENC ... SAE J1113-11 Conducted transient immunity - Pulse 5b suppressed load dump (45 Volts).

Humidity ... US MIL-STD 810E method 507.3 Procedure three

Spray of Salt ... US MIL-STD 810E method 509.3 Procedure one

Shock ... MS1-40G 11 ms sawtooth

Random Vibration ... Random 0.3 G² Hz, 10-2000Hz (22.1 grams) 3h/axis Sine, 5G 2.5mmpeak to peak, 5-2000Hz 3h/axis, 60min dwell, 1 octave/min

Drop ... SAE J1211, Paragraph 4.8.3 (modified)

Thermal shock ... SAE j1455, Paragraph 4.1.3.2

Protection from ingress ... IP56 per EN60529

Electrical Load, Power, Connection Electrical Transient ... 2 J per SAE J1455, Paragraph 4.11.2.2.1

LCG 1

Software Programming

The LCG 1is a digital control system with no externally accessible adjustment. A software is available in order to help the distributor or original equipment manufacture OEM with each phase of the application, manufacture and field service. The software for the LCG 1 is compatible with Windows 2000 XP software. The software gives the distributor and the OEM the ability to perform the following procedures:

The Logic Control Governor service tools are available from your Caterpillar dealer.

• Programming and date harness

Note: The programming harness must not be connected to the computer when the engine is started.

Software Installation

• The software is available on a CD.

• Input software files to the LCG 1.

• Fault codes can be viewed by a technician.

• Logic control governor software update during the field service

Locate the execute file. Double click the execute file. Follow the instruction on the screen.

Illustration 39	g01272156
Screen for the LCG 1

Illustration 40	g01272170
Screen for the LCG 1

Once the software setup is completed, restart the computer in order to update the registry.

Illustration 41	g01272258
Screen for the LCG 1

Select the program for the LCG 1 from the menu. The LCG Control Service Tool will appear for a short time. The LCG Control Service Tool will then disappear.

This is the first screen that appears when the graphic user interface (GUI) is installed. Refer to illustration 42. To use the GUI flash tool, the user must have a LCG1 with a supported firmware revision. The user must have access to a valid configuration file.

Illustration 42	g01290773

The GUI supports firmware revisions. The dialog box in the center of the screen will indicate that a LC SPD/TOPPING configuration format will be used. If the system has a different configuration format, contact your Caterpillar dealer.

IDENTITY CONTROL-. This Identifies the version of Firmware that is used by the LCG. Ensure that theLCG is connected to the computer via a Programming harness.

IMPORT CONFIG FILE - opens an existing configuration file. Use the internet browser to select the desired file. (Configuration files use a *.lcs extension.)

Note: In working with the LCG, the power must be cycled from time to time. The user will be prompted to turn power to the ON position or to the OFF position. If the power cycle is not completed in ten seconds, a message will appear. The message prompts the user to retry. The message also prompts the current activity to be stopped.

Once a valid file or valid LCG has been identified, a screen is displayed. Refer to illustration 43. The box in the center of the screen determines the version of the LCG.

Illustration 43	g01290774

The configuration menu will allow the user to download different configuration files to the LCG.

Illustration 44	g01290778

If you select the Write Configuration File To LCS button you will be able to select a file from a location of your choice. Refer to illustration 45.

Illustration 45	g01290779

Speed governor applications

Show/hide table

NOTICE
Know in advance how to safely shut off the engine during normal and emergency stop conditions. When power to the governor is shut off, this does not guarantee a shutdown; it depends on the final application. Safety needs to be the primary thought during this procedure.

Speed governor applications require the speed control loop is calibrated for load transients and steady state conditions. Use this procedure to derive the values of the speed control coefficients (reset, gain, and compensation) for a fixed engine speed.

Gain will determine the speed that the control system responds to an error, when the speed reference is changed or the load changes. A value that is too high will result in fast oscillations in speed. A value that is too small will result in poor control performance. This may result in slower oscillations.

A reset prevents a slow surge at a steady state. A reset prevents a slow surge at a steady state. Restrictions are present when the speed is altered. The error returns to zero after a speed is altered. A value that is too high will result in low variations of frequency in engine speed. The actuator will tend to hit the stops. A value that is too high is indicated by an over restricted condition or a speed error that returns too slowly to zero. A value that is too low is indicated by an under restricted condition. The speed value may overshoot the reference. The speed valve may reset with several restricted oscillations. A value that is too low a value will result in a slow, low amplitude surge of speed about the speed reference.

Compensation term compensates for actuator lag. Compensation term adjusts the rate of change in the output of the actuator when the load changes in a value. A value that is too low will result in under damped control. A value that is too high will result in excessive movement of an actuator at high frequency.

Illustration 46	g01273935

Viewing and Resetting Fault Codes

To view the control fault register,, select the View Fault Codes option that is located in the Fault Code Menu. The program will display the part of the error that is in the register. Configuration error, overspeed error or failsafe error. A configuration error is the result of not downloading a configuration file into a new control. Overspeed and failsafe errors relate to issues with the MPU or the connection to an ignition system.

Illustration 47	g01290780

Reset Fault Codes

Erase the contents of the control fault register by selecting the Reset Fault Codes option. The program will reset the state of all errors.