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

Illustration 1	g00614752
Schematic For Unexpected Shutdown

Note: A slave relay is used only on Series 3500 engines with a Woodward 2301A and no fuel shutoff solenoid.

Illustration 2	g00614755
Fuel Control Relay For ETR Systems

Note: For Series 3408 and Series 3412 engines, the AFCR should be connected to SR terminal 87 instead of the fuel solenoid, and provided with F16.

Note: A slave relay is used only on Series 3500 engines with a Woodward 2301A and no fuel shutoff solenoid.

Illustration 3	g00614757
Fuel Control Relay On ETS Systems

The CID 566 alerts the operator that the GSC did not control the engine shutdown. The GSC normally controls all engine shutdowns. 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.

Note: An unexpected shutdown fault will initiate a signal from the shunt trip circuit breaker.

Note: Diagnostic codes are created when the harness connector (40 contact) is disconnected from the GSC during these troubleshooting procedures. Clear these created diagnostic codes after the particular fault is corrected. In a properly operating system, when the harness connector is removed from the GSC, the following diagnostic codes are recorded.

• CID 100 FMI 3 pressure sensor (engine oil)

• CID 110 FMI 3 temperature sensor (engine coolant)

• CID 111 FMI 3 fluid level sensor (engine coolant)

• CID 190 FMI 3 speed sensor (engine)

• CID 331 FMI 2 switch (engine control)

• CID 336 FMI 2 switch (engine control)

Procedure

The following condition is a possible cause of a CID 566 FMI 7:

• 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 has been 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 by shutting off the fuel and air to the engine. The resulting voltage measurements would then be the opposite of what is expected in the procdures.

   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. If the generator set is equipped with an electronic governor, check the speed sensor.

   7. 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 20. 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 Governor And Rack.

   1. Remove fuse F4 from the relay module.

   2. Prepare to monitor the movement of the governor linkage and the fuel rack.

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

   4. Observe the governor and the fuel rack.

      Expected Result: The governor linkage and fuel rack should move in the direction to turn on the fuel.

      Results:

      • OK - The fault is in the engine or fuel system. Refer to the corresponding Engine Service Manual. STOP.

      • Not OK - Cannot see the governor linkage and fuel rack move in the direction to turn on the fuel. Proceed to 5.

5. Identify Fuel System. Determine the type of fuel solenoid used on the genset: ETR (energize to run) or ETS (energize to shutoff). Refer to the model number of the EMCP II on the inside bottom of the control panel and to the 129-4053103-1582 print included within the panel to identify the type of fuel solenoid.

   1. Check setpoint P01 for proper programming (0=ETR, 1=ETS). See Systems Operation, "Engine/Generator Setpoint Viewing OP2".

      Note: For Series 3500 product only, if an electronic governor is present and a fuel solenoid is not present, go directly to 15.

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

      Results:

      • OK - Proceed to 6.

      • Not OK - Setpoint P01 is NOT programmed correctly. Reprogram setpoint PO1, see See Systems Operation, "Setpoint Programming OP5".

6. Check Voltage At Fuel Solenoid. Fuse F4 remains removed from the relay module.

   1. Prepare to measure the voltage across the terminals of the fuel solenoid on the engine.

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

   3. At the fuel solenoid, measure the voltage across the terminals.

      Expected Result: For ETR fuel solenoids, the voltage should be ± 2.0 DCV of the system voltage measured in 3. For ETS fuel solenoids, the voltage should be from 0 to 2.0 DCV.

      Results:

      • OK - The fault is with the governor or fuel rack. If an electronic governor is present, proceed to 15. Refer to the appropriate Service Manual. STOP.

      • Not OK (ETR type) - Voltage is low. Proceed to 7.

      • Not OK (ETS type) - Voltage is high. Proceed to 13.

7. (ETR). Check Fuses.

   1. Turn the ECS to OFF/RESET.

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

   3. If the engine is a Series 3408 or Series 3412 and has the auxiliary fuel control relay (AFCR) installed, also check F16 on the rear inside wall of the panel.

      Expected Result: None of these fuses should be blown (open).

      Results:

      • OK - Proceed to 8.

      • Not OK - One or more of the fuses are blown. Proceed to 9.

8. (ETR). Check Voltage At 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 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 previously measured in 3.

      Results:

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

      • Not OK - Voltage is low. Proceed to 10.

9. (ETR). Troubleshoot Blown Fuse. This Step continues troubleshooting from 7. See the "Main Chassis Wiring Diagram" in Testing and Adjusting, "Schematics & Wiring Diagrams" for reference.

   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 battery negative (B-).

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

      • If the blown fuse is F16 (on the sub-panel), measure the resistance from terminal 2 (load side) of the fuse holder to battery negative (B-).

      Expected Result: For a fuse that is blowing, the circuit resistance should be less than 3 ohms.

      Results:

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

      • Not OK - If a resistance is less than 3 ohms, there is a short to battery negative (B-). (NOTE: On some ETR fuel systems with a dual coil fuel 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 until the faulty component or wire is isolated. Repair or replace 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.

10. (ETR). Check Low Voltage Condition. This Step continues troubleshooting from 8. Fuse F4 remains removed from the relay module. See the "Main Chassis Wiring Diagram" in Testing and Adjusting, "Schematics & Wiring Diagrams". Prepare to make voltage measurements at the relay module.

    1. Turn the ECS to OFF/RESET and then 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 in Step 3.

       Results:

       • OK - Proceed to Step 11.

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

11. (ETR) Check For Other Faults.

    1. Make sure that no other faults are active.

    2. Check the upper display for any active faults.

       Expected Result: Only CID 566 FMI 7 is active.

       Results:

       • OK - Only CID 566 FMI 7 is active. Proceed to Step 12.

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

12. Recheck Voltage.

    1. Recheck the voltage on RM-15 of the relay module. See 8.

       Expected Result: The voltage should be ± 2.0 DCV of the system voltage 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 solenoid. Repair the wiring. See the "Main Chassis Wiring Diagram" in 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.

13. (ETS). Check Voltage At Relay Module. This Step continues troubleshooting from 6. Fuse F4 remains removed from the relay module. Prepare to measure the voltage at the relay module.

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

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

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

       Results:

       • OK - Voltage is correct. Therefore, a wire or a component between RM-15 of the relay module and the fuel solenoid is shorted to battery positive (B+). Repair the circuit. See the "Main Chassis Wiring Diagram" in Testing and Adjusting, "Schematics & Wiring Diagrams". STOP.

       • Not OK - Voltage is high. Proceed to 14.

14. (ETS) Check FCR And EFCR. Fuse F4 remains removed from the relay module.

    1. Remove fuse F2 from the relay module.

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

    3. Make sure that "K7" is not shown on the lower GSC display. If "K7" is showing, make sure that no other faults are active.

    4. At the relay module, measure the resistance from RM-4 to RM-15. A measurement of less than 100 ohms indicates there is a faulty component shorting RM-15 to RM-4.

    5. Disconnect the wire from RM-4 of the relay module and watch for a change in resistance.

       Expected Result: Both measurements should be greater than 10k ohms.

       Results:

       • OK - Both resistance measurements are greater than 10k ohms. Check for a short from battery positive (B+) to RM-15 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 - The resistance increases to greater than 10k ohms as the wire on RM-4 of the relay module is removed. Repair the shorted wiring to the emergency fuel control relay (EFCR) or replace the EFCR as necessary. STOP.

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

15. Check Supply Voltage Of Electronic Governor. This Step continues troubleshooting from 5 or 6. Fuse F4 remains removed from the relay module. Prepare to make a voltage measurement from the electronic governor to the relay module.

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

    2. Measure the voltage from the positive supply terminal of the electronic governor to the B- terminal of the relay module.

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

       Results:

       • OK - Supply voltage is correct. The fault is in the electronic governor or actuator system. For the 2301A governor, refer to module Systems Operation & Testing and Adjusting, SENR4676. For the 2301A load sharing governor, refer to module Systems Operation & Testing and Adjusting, SENR3585. For 524 and 1724 electrically powered governor systems, refer to module General Service Information, SENR6430. STOP.

       • Not OK - Supply voltage is low. Check fuse F6 on the relay module and fuse F11 on the rear wall of the panel. If blown, proceed to 9. If fuse is OK, proceed to 16.

16. Check Voltage At 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 to START.

    2. At the relay module, measure the voltage from RM-24 to the B- terminal of the relay module.

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

       Results:

       • OK - Voltage is correct. There is an open between RM-24 of the relay module and the electronic governor. Check the wiring. See the "Main Chassis Wiring Diagram" in Testing and Adjusting, "Schematics & Wiring Diagrams". STOP.

       • Not OK - Voltage is low. Proceed to 17.

17. Check Low Voltage Condition. Fuse F4 remains removed from the relay module. See the "Main Chassis Wiring Diagram" in Testing and Adjusting, "Schematics & Wiring Diagrams" for reference. Prepare to make voltage measurements at the relay module.

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

    2. At the relay module, measure the voltage from RM-8 to the B- terminal.

    3. At the relay module, measure the voltage from RM-35 to the B- terminal.

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

       Results:

       • OK - Voltage is correct. Proceed to Step 18.

       • Not OK - Voltage is not correct. Check the wiring and recheck the fuse F6. STOP.

18. Check For Faults.

    1. Make sure that no other faults are active.

    2. Check the upper display for any active faults.

       Expected Result: Only CID 566 FMI 7 is active.

       Results:

       • OK - Only CID 566 FMI 7 is active. Proceed to Step 19.

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

19. Recheck The Voltage.

    1. Recheck the voltage on RM-24 of the relay module. See 16.

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

       Results:

       • OK - The voltage is correct. There is an open circuit between RM-24 of the relay module and the fuel solenoid. Repair the wiring. See the "Main Chassis Wiring Diagram" in 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.

20. Check Voltage At Air Shutoff Solenoid. Prepare to make a voltage measurement at the air shutoff solenoid (air solenoid may activate for as little as 15 seconds).

    1. Remove fuse F4 from the relay module.

    2. Turn the ECS to OFF/RESET and then 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 remains tripped or cannot be reset, the fault is in the air shutoff. Refer to the Engine Service Manual. STOP.

       • Not OK - Voltage is high. Proceed to 21.

21. Check Voltage At 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 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 previously measured in 3.

       Results:

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

       • Not OK - The voltage is high. Proceed to 22.

22. Check 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 faults are active.

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

       Expected Result: The resistance should be greater than 10k ohms.

       Results:

       • OK - Resistance is greater than 10k ohms. Check for a short from battery positive (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.