Electronic Modular Control Panel II (EMCP II) For PEEC Engines Caterpillar

Illustration 1	g00597871
System Schematic For Starting Motor Relay (SMR)

To find the cause of an overcrank shutdown, perform this procedure.

1. Preliminary Step. Initial Check.

   Before you proceed with the troubleshooting procedures, do the following preliminary checks.

   1. Check for active diagnostic codes with the exception of the CID 566 FMI 7. Also check for other flashing indicators on the GSC. If the fault is present, then correct the fault first. Go to the appropriate procedure for that fault.

   2. Check the fuel level and quality. Refer to the Engine Service Manual.

   3. Check for a plugged fuel filter. Refer to the Engine Service Manual.

   4. Check for a plugged air filter. Refer to the Engine Service Manual.

   5. Check the air shutoff solenoid (if equipped) for activation. The solenoid must be deactivated in order for the engine to start. See Testing And Adjusting, "Troubleshooting Diagnostic Codes".

   6. Check the optional prelube system for proper operation. See "DC - Schematic Prelube Pump Option" in Testing And Adjusting, "Schematics And Wiring Diagrams".

   7. Check fuse "F4" on the relay module. If either fuse is blown, proceed to 10.

   8. Check the engine starting system and the fuel system. (To check the fuel control solenoid, see Testing And Adjusting, "Troubleshooting Diagnostic Codes".) If there is a fault, refer to the Engine Service Manual. If there is no engine fault or fuel system fault, proceed to 2.

2. Check setpoints.

   This step checks setpoints P17 (total cycle crank time) and P18 (cycle crank time).

   1. View the setpoints and note the setpoints P17 and P18. See Systems Operation, "Engine/Generator Setpoint Viewing OP2".

   2. Compare the setpoints that are viewed with the setpoints that are specified for the particular generator set. The factory default values are 90 seconds for P17 and 10 seconds for P18.

      Note: Engines that are equipped with prelube pumps may require cycle crank times of thirty seconds or more.

      Expected Result: The setpoint value that is viewed and the setpoint value that is specified should agree.

      Results:

      • OK - Proceed to 3.

      • Not OK - The setpoints do not agree. Reprogram setpoints P17 and P18. See Systems Operation, "Engine/Generator Programming OP5". STOP.

3. Check the battery voltage.

   1. Make sure that the engine is off. Measure the system voltage at the batteries.

      Expected Result:

      For 24 volt systems, the voltage should be from 24.8 to 29.5 DCV.

      For 32 volt systems, the voltage should be from 33.1 to 39.3 DCV.

      Results:

      • OK - Proceed to 4.

      • NOT OK - Further checking of the battery system is necessary. See Testing And Adjusting, "Troubleshooting Diagnostic Codes". STOP.

4. Check the procedure for starting the engine.

   Steps 4 through 9 require voltage measurements to be made during simulated engine cranking. The starting motor is disabled.

   Note: The GSC is attempting to crank whenever the K4 indicator is being displayed on the lower display. Be aware of the 10 second crank cycle that is factory set. Ensure that the K4 indicator is ON while you are making the following measurements. If necessary, a helper could observe the GSC display. More than one start may be required to complete this test.

   1. Disconnect the wire for B+ on the pinion solenoid of the starting motor. The wire remains disconnected for all of the remaining steps of this procedure.

   2. Prepare to measure the DC voltage from the disconnected "B+" pinion solenoid wire to "B-" (ground).

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

   4. Measure the voltage.

      Expected Result: The voltage should be the system voltage that was noted in 3, ± 2.0 DCV.

      Results:

      • OK - Therefore, the starting motor is faulty. Repair the starting motor or replace the starting motor. Refer to the Engine Service Manualor the Service Manual, "Starting Motor". STOP.

      • NOT OK - Proceed to 5.

5. Check the procedure for starting the engine.

   The conditions of 4 remain. "B+" wire is disconnected from the pinion solenoid.

   1. In the junction box, prepare to measure the DC voltage from "B-" (ground) to the terminal TS1-25.

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

   3. Measure the voltage.

      Expected Result: The voltage should be the same as the system voltage that is noted in 3, ±2.0 DCV.

      Results:

      • OK - Therefore, the engine wire harness is faulty. Repair the engine wire harness or replace the engine wire harness. See the Testing And Adjusting, "Schematics And Wiring Diagram". STOP.

      • Not OK - Proceed to 6.

6. Check the procedure for starting the engine.

   The conditions of 4 remain. "B+" wire is disconnected from the pinion solenoid.

   1. Prepare to measure the voltage from terminal TS1-5 in the generator housing to "B-" (ground).

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

   3. Measure the voltage.

      Expected Result: The voltage should be the same as the system voltage noted in 3, ±2.0 DCV.

      Results:

      • OK - Therefore, the starting motor magnetic switch (SMMS) is faulty. Also, the wiring could be faulty. Troubleshoot the SMMS and the wiring. See the Testing And Adjusting, "Schematics And Wiring Diagram". STOP.

      • Not OK - Proceed to 7.

7. Check the procedure for starting the engine.

   The conditions of 4 remain. "B+" wire is disconnected from the pinion solenoid.

   1. Prepare to make a voltage measurement from RM-18 of the relay module to "B-" (ground).

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

   3. Measure the voltage.

      Expected Result: The voltage should be the same as the system voltage noted in 3, ±2.0 DCV.

      Results:

      • OK - Therefore the emergency stop push button (ESPB) or the related wiring is faulty. Troubleshoot the ESPB and the related wiring. See the Testing And Adjusting, "Schematics And Wiring Diagram". STOP.

      • NOT OK - Proceed to 8.

8. Check the procedure for starting the engine.

   The conditions of 4 remain. "B+" wire is disconnected from the pinion solenoid.

   1. Prepare to measure the DC voltage from RM-6 of the relay module to "B-" (ground).

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

   3. Measure the voltage.

      Expected Result: The voltage should be the same as the system voltage noted in 3, ±2.0 DCV.

      Results:

      • OK - Therefore, the relay module is faulty. Replace the relay module. First, make sure that the "K4" indicator is ON. See Testing And Adjusting, "Relay Module - Replace". STOP.

      • Not OK - Proceed to 9.

9. Check the procedure for starting the engine.

   The conditions of 4 remain. "B+" wire is disconnected from the pinion solenoid.

   1. Prepare to measure the DC voltage from RM-33 of the relay module to "B-" (ground).

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

   3. Measure the voltage.

      Expected Result: The voltage should be the same as the system voltage noted in 3, ±2.0 DCV.

      Results:

      • OK - Therefore, fuse "F4" is blown. Proceed to 10.

      • Not OK - Therefore the B+ terminal or the wiring to RM-33 is faulty. Repair the wiring or replace the wiring. See the Testing And Adjusting, "Schematics And Wiring Diagram". STOP.

10. Troubleshoot a blown fuse.

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

    2. At the relay module, measure the resistance from RM-18 to "B-" (ground).

       Expected Result: A short to "B-" (ground) will measure 5 ohms or less.

       Results:

       • OK - Resistance is greater than 5 ohms and fuse is no longer blowing. Carefully check ALL the wires that are connected to the appropriate terminal of the relay module for abrasion or worn spots in the insulation. These wires could cause a short. Check the wires in the panel, the generator panel, and the engine harness. Refer to the various wiring diagrams. If necessary, repair the wiring or replace the wiring. STOP.

       • Not OK - Resistance is 5 ohms or less. There is a short to ground. See the Testing And Adjusting, "Schematics And Wiring Diagram". Remove one component or wire at a time that is in series with RM-18 until the faulty component or wire is isolated. Repair the faulty component or replace the faulty component. Repair wiring or replace wiring. STOP.