Electronic Modular Control Panel II (EMCP II) for EUI Engines Caterpillar

Illustration 1	g00479969
System Schematic For Electronic Governor Relay (EGR)

Illustration 2	g00488518
System Schematic For Air Shutoff Relay (ASR)

The CID 566 alerts the operator that the GSC did not control the engine shutdown. Any fault shutdown that is initiated solely by the engine ECM will result in a CID 566 on the GSC. If an outside influence causes the engine to shut down, the GSC indicates a CID 566. There is only one failure mode for a CID 566 and the mode is FMI 7 (faulty mechanical response).

The diagnostic code causes the following sequence of events:

• On a running engine, the GSC detects that the engine speed has dropped from the rated speed to 0 rpm when the GSC has not called for a shutdown.

• The GSC determines that no fault for the engine speed sensor is present that explains the drop in the speed signal.

• The GSC indicates a CID 566 FMI 7 and the GSC disables the engine from running.

Procedure

The possible cause of a CID 566 FMI 7 is that a component that is not under the control of the GSC has caused an engine shutdown.

The GSC treats this diagnostic code as a shutdown fault. Clear the diagnostic code from the fault log after troubleshooting is complete.

Note: This procedure requires many voltage measurements during simulated engine cranking. The fuse for the starting motor "F4" on the relay module is removed in order to prevent the activation of the starting motor. Voltage measurements must be made quickly before the total cycle crank time (setpoint P17) elapses. The total cycle crank time is defaulted to ninety seconds. See Systems Operation, "Engine/Generator Programming OP5". If a voltage measurement takes too long (more than 90 seconds), the GSC indicates an overcrank fault. The indicator for the overcrank shutdown will FLASH. In order to continue with a voltage measurement, the overcrank fault must be reset by turning the ECS to OFF/RESET. Then turn the ECS to START.

1. Perform an initial check.

   Before proceeding with the troubleshooting procedures, do the following steps:

   1. Make sure that there are NO OTHER ACTIVE FAULTS. Erroneous troubleshooting and needless replacement of parts can be caused by a failure to check for other diagnostic codes. The operator will make many voltage measurements while the GSC is attempting to crank the engine. The GSC detects other diagnostic codes. If the GSC detects other diagnostic codes, the GSC will prevent the starting of the engine by shutting off the fuel and the air.

   2. Check the fuel level and the fuel quality.

   3. Check for a plugged fuel filter.

   4. Check for a plugged air filter.

   5. Refer to the Engine Service Manual if there is an obvious engine fault. Also, refer to the Engine Service Manual if there is an obvious fault with the fuel system.

   6. Check the air shutoff solenoid for activation. If the air shutoff solenoid is activated and the air shutoff solenoid cannot be deactivated, begin troubleshooting with 15. Otherwise begin troubleshooting with 2.

2. Verify the diagnostic code.

   1. Observe the upper display. Check that the CID 566 FMI 7 is showing.

      Expected Result: A CID 566 FMI 7 is showing as an active fault.

      Results:

      • No - A CID 566 FMI 7 is NOT showing. No active CID 566 FMI 7 exists. STOP.

      • Yes - Only a CID 566 FMI 7 is showing. Proceed to 3. (If an inactive CID 566 FMI 7 is showing in the fault log, check the history of the genset and proceed to 3.)

3. Check the system voltage.

   1. Ensure that the engine is off. Measure the system voltage at the battery. Make a note of this measurement. The measurement for the system voltage is used for comparison in future steps of this procedure.

      Expected Result: For 24 volt systems, the system voltage should be from 24.8 to 29.5 DCV. For 32 volt systems, the system voltage should be from 33.1 to 39.3 DCV.

      Results:

      • OK - Proceed to 4.

      • NOT OK - System voltage is NOT correct. For troubleshooting, see the procedure for system voltage. STOP.

4. Check the setpoint P01.

   1. Check the setpoint P01 for proper programming ("0" for ETR and "1" for ETS). See Systems Operation, "Setpoint Viewing OP2".

      Expected Result: Setpoint P01 should be programmed to match the type of fuel control solenoid that is used on the genset.

      Results:

      • OK - Proceed to 5.

      • Not OK - Setpoint P01 is NOT programmed correctly. Reprogram setpoint P01. See Systems Operation, "Engine/Generator Programming OP5".

5. Check the fuses.

   1. Turn the ECS to OFF/RESET.

   2. Check fuses "F2" and "F10" on the relay module.

      Expected Result: None of these fuses should be blown.

      Results:

      • OK - Proceed to 6.

      • NOT OK - One or more of the fuses are blown. Proceed to 7.

6. Check the voltage at the relay module.

   Fuse "F4" remains removed from the relay module.

   1. Prepare to measure the voltage from RM-15 to the B- terminal of the relay module.

   2. Turn the ECS to OFF/RESET and then turn the ECS to START.

   3. At the relay module, measure the voltage from RM-15 to the B- terminal.

      Expected Result: The voltage should be ± 2.0 DCV of the system voltage that was previously measured in 3.

      Results:

      • OK - Therefore, there is an open circuit between RM-15 of the relay module and the fuel control solenoid. Repair the circuit. See the preceding System Schematic. STOP.

      • NOT OK - Voltage is low. Proceed to 8.

7. Troubleshoot the blown fuse.

   This test continues troubleshooting from 5. For reference, see the preceding System Schematics and Testing And Adjusting, "Schematics and Wiring Diagrams".

   1. The ECS remains in the OFF/RESET position.

   2. Remove the fuse that is blown.
      • If the blown fuse is "F2", measure the resistance from RM-15 of the relay module to ground (B-).

      • If the blown fuse is "F10", measure the resistance from RM-39 of the relay module to ground (B-).

      Expected Result: The resistance of the circuit should be less than 3 ohms for the circuit with the fuse that is blown.

      Results:

      • OK - Resistance is greater than 3 ohms and fuse is no longer blowing. Carefully check ALL wires that are connected to the appropriate terminal of the relay module for abrasion or worn spots in the insulation that could be causing the short. Check the wires in the panel and the generator panel. Also check the wires on the engine harness. Refer to the various wiring diagrams. Repair the wiring or replace wiring, if necessary. STOP.

      • NOT OK - If a resistance is less than 3 ohms, there is a short to ground (B-). (On some ETR fuel systems with a dual coil fuel control solenoid, the correct normal resistance can measure less than 1 ohm.) Remove one component or wire at a time that is in series with the load side of the fuse terminal. Remove a component or wire until the faulty component or wire is isolated. Repair the faulty component or wiring. If necessary, replace the faulty component or wiring. STOP.

      • NOT OK - If a resistance is greater than 3 ohms and the fuse still blows when all wires are removed from the appropriate terminal, replace the relay module. See Testing And Adjusting, "Relay Module - Replace". STOP.

8. Check the condition of the low voltage.

   This test continues troubleshooting from 6. Fuse "F4" remains removed from the relay module. For reference, see the "Generator Set Wiring Diagram" in the Testing And Adjusting, "Schematics & Wiring Diagrams". Prepare to make voltage measurements at the relay module.

   1. Turn the ECS to OFF/RESET and then turn the ECS to START.

   2. At the relay module, measure the voltage from RM-4 to the B- terminal and from RM-31 to the B- terminal.

      Expected Result: The voltage should be ± 2.0 DCV of the system voltage that was measured previously in 3.

      Results:

      • OK - Proceed to 9.

      • NOT OK - Voltage is NOT correct. Check the wiring and recheck the fuse "F2". STOP.

9. Check that the diagnostic code exists.

   1. Make sure that no other diagnostic codes are active.

   2. Check the upper display for any active diagnostic codes.

      Expected Result: Only CID 566 FMI 7 is active.

      Results:

      • OK - Only CID 566 FMI 7 is active. Proceed to 10.

      • NOT OK - A diagnostic code other than CID 566 FMI 7 is active. Correct the other diagnostic code. Proceed to the corresponding troubleshooting procedure. STOP.

10. Check the system voltage.

    1. Recheck the voltage on RM-15 of the relay module. See 6.

       Expected Result: The voltage should be ± 2.0 DCV of the system voltage that was previously measured in 3.

       Results:

       • OK - The voltage is correct. There is an open circuit between RM-15 of the relay module and the fuel control solenoid. Repair the wiring. See the "Generator Set Wiring Diagram" in the Testing And Adjusting, "Schematics & Wiring Diagrams". STOP.

       • NOT OK - The voltage remains low, replace the relay module. See Testing And Adjusting, "Relay Module - Replace". STOP.

11. Check the voltage at the relay module.

    Fuse "F4" remains removed from the relay module. Prepare to make a voltage measurement at the relay module.

    1. Turn the ECS to OFF/RESET and then turn the ECS to START.

    2. At the relay module, measure the voltage from RM-15 to the B- terminal of the relay module.

       Expected Result: The voltage should be ± 2.0 DCV of the system voltage that was previously measured in 3.

       Results:

       • OK - Voltage is correct. There could be an open between RM-15 of the relay module and the electronic governor. There could also be an open between the B- terminal of the relay module and the electronic governor. Check the slave relay and the wiring. See the "Generator Set Wiring Diagram" in the Testing And Adjusting, "Schematics & Wiring Diagrams". STOP.

       • NOT OK - Voltage is low. Proceed to 12.

12. Check the condition of the low voltage.

    Fuse "F4" remains removed from the relay module. For reference, see the preceding System Schematic and the "Generator Set Wiring Diagram" in the Testing And Adjusting, "Schematics & Wiring Diagrams". Prepare to make voltage measurements at the relay module.

    1. Turn the ECS to OFF/RESET and then turn the ECS to START.

    2. At the relay module, measure the voltage from RM-4 to the B- terminal.

    3. At the relay module, measure the voltage from RM-31 to the B- terminal.

       Expected Result: the voltage should be ± 2.0 DCV of the system voltage that was previously measured in 3.

       Results:

       • OK - Voltage is correct. Proceed to 13.

       • NOT OK - Voltage is not correct. Check the wiring and recheck the fuse "F2". STOP.

13. Check that the diagnostic code exists.

    1. Make sure that no other diagnostic codes are active.

    2. Check the upper display for any active diagnostic codes.

       Expected Result: Only CID 566 FMI 7 is active.

       Results:

       • OK - Only CID 566 FMI 7 is active. Proceed to 14.

       • NOT OK - A diagnostic code other than CID 566 FMI 7 is active. Correct the other diagnostic code. Proceed to the corresponding troubleshooting procedure. STOP.

14. Check the system voltage.

    1. Recheck the voltage on RM-15 of the relay module. See 11.

       Expected Result: The voltage should be ± 2.0 DCV of the system voltage that was previously measured in 3.

       Results:

       • OK - The voltage is correct. There is an open circuit between RM-15 of the relay module and the fuel control solenoid. Check the slave relay, the fuel control relays ("1FCR" and "2FCR") and the wiring. See the "Generator Set Wiring Diagram" in the Testing And Adjusting, "Schematics & Wiring Diagrams". STOP.

       • NOT OK - The voltage remains low, replace the relay module. See Testing And Adjusting, "Relay Module - Replace". STOP.

15. Check the voltage at the air shutoff solenoid.

    This test continues troubleshooting from the preliminary step (initial check). Prepare to make a voltage measurement at the air shutoff solenoid. (The air shutoff solenoid may be active for 15 seconds.)

    1. Remove fuse "F4" from the relay module.

    2. Turn the ECS to OFF/RESET and then turn the ECS to START.

    3. At the air shutoff solenoid, measure the voltage across the terminals of solenoid.

       Expected Result: The voltage should be from 0 to 2.0 DCV.

       Results:

       • OK - Voltage is correct. If the air shutoff solenoid cannot be reset then the fault is in the air shutoff solenoid. Refer to the Engine Service Manual. STOP.

       • NOT OK - Voltage is high. Proceed to 16.

16. Check the voltage at the relay module.

    Fuse "F4" remains removed from the relay module. Prepare to make a voltage measurement at the relay module.

    1. Turn the ECS to OFF/RESET and then turn the ECS to START.

    2. At the relay module, measure the voltage from RM-19 to the B- terminal.

       Expected Result: The voltage should be ± 2.0 DCV of the system voltage that was previously measured in 3.

       Results:

       • OK - The voltage is correct. A wire or a component that is located between RM-19 of the relay module and the air shutoff solenoid is shorted to the battery (B+). Repair the circuit. See the "Generator Set Wiring Diagram" in the Testing And Adjusting, "Schematics & Wiring Diagrams". STOP.

       • NOT OK - The voltage is high. Proceed to 17.

17. Check the ASR.

    Fuse "F4" remains removed from the relay module.

    1. Remove fuse "F3" from the relay module.

    2. Turn the ECS to OFF/RESET.

    3. Make sure that "K6" is not shown on the lower GSC display. (If "K6" is showing, make sure that no other diagnostic codes are active.)

    4. At the relay module, measure the resistance from RM-5 to RM-19. A measurement of less than 100 ohms indicates that the air shutoff relay is shorted.

       Expected Result: The resistance should be greater than 10000 ohms.

       Results:

       • OK - Resistance is greater than 10000 ohms. Check for a short from the battery (B+) to RM-19 of the relay module. Repair the shorted wiring. If the short is internal to the relay module, replace the relay module. See Testing And Adjusting, "Relay Module - Replace". STOP.

       • NOT OK - Resistance is less than 100 ohms. The short is internal to the relay module. Replace the relay module. See Testing And Adjusting, "Relay Module - Replace". STOP.