Electronic Modular Control Panel II (EMCP II) Caterpillar

Illustration 1	g00681895
System Schematic For Electronic Governor Relay (EGR) On EUI Engines

Illustration 2	g00681904
System Schematic For Air Shutoff Relay

The purpose of the CID 0566 is to alert the operator that the GSC did not control the engine shutdown. A shutdown fault initiated solely by the engine ECM will result in a CID 566 diagnostic code on the GSC. The GSC normally controls all engine shutdown functions for both normal operation and fault shutdowns. If an outside influence causes an engine shutdown, the GSC shows a CID 0566. There is only one failure mode for a CID 0566. This failure mode is FMI 07. FMI 07 is an improper mechanical response.

The diagnostic code causes the following sequence of events:

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

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

• The GSC declares a CID 0566 FMI 07 and disables the engine from running or starting.

The possible cause of a CID 0566 FMI 07 is listed below.

• A component that is not under the control of the GSC has caused an engine shutdown.

The GSC treats a CID 0566 FMI 07 as a shutdown fault. Clear the fault from the fault log after troubleshooting is complete.

Note: This procedure requires many voltage measurements during simulated engine cranking. The starting motor fuse "F4" on the relay module is removed in order to prevent activating the starting motor and actual engine cranking does not occur. Voltage measurements must be made quickly before the total cycle crank time (setpoint P17) elapses. The total cycle crank time is 90 seconds. See Systems Operation, "Engine/Generator Programming OP5-0". If a measurement of the voltage takes more than 90 seconds, the GSC shows an overcrank fault. The overcrank shutdown indicator will FLASH. In order to continue with a voltage measurement, the overcrank fault must be reset by turning the engine control switch (ECS) to OFF/RESET. Then, turn the ECS to START.

Test Step 1. PERFORM AN INITIAL CHECK.

1. Make sure that there are NO OTHER ACTIVE FAULTS. This means that there are no diagnostic codes which are showing on the upper display. This means that no shutdown or alarm indicators are flashing. Failure to do so may result in erroneous troubleshooting and needless replacement of parts. The operator will make many voltage measurements while the GSC is attempting to crank the engine. If the GSC detects other faults, it will prevent starting by shutting off the fuel and air to the engine. The resulting voltage measurements would then be the exact opposite of the voltage which is expected in the procedures.

2. Check the fuel level and quality.

3. Check for a plugged fuel filter.

4. Check for a plugged air filter.

5. Refer to the Service Manual for the engine if there is an obvious fault with the engine or the fuel system.

6. Check the operation of the air shutoff solenoid (if present).

Expected Result:

The air shutoff solenoid activates and the air shutoff solenoid deactivates.

Note: If there is no air shutoff solenoid present, proceed with the "YES" statement.

Results:

• YES - The air shutoff solenoid can be activated and the air shutoff solenoid can be deactivated. Proceed to test step 2.

• NO - The air shutoff solenoid can NOT be activated and the air shutoff solenoid can NOT be deactivated. Proceed to test step 11.

Test Step 2. VERIFY THE DIAGNOSTIC CODE.

1. Check if the CID 0566 FMI 07 is showing. This means that the CID 0566 FMI 07 is active.

Expected Result:

The CID 0566 FMI 07 is showing as an active fault.

Results:

• OK - Only a CID 0566 FMI 07 is showing. Proceed to test step 3.

• NOT OK - A CID 0566 FMI 07 is NOT showing. No active CID 0566 FMI 07 exists. Stop.

Test Step 3. CHECK THE SYSTEM VOLTAGE.

1. With the engine off, measure the system voltage at the battery. Make a note of this measurement. This measurement of the system voltage is used for comparison in future steps of this procedure.

Expected Result:

For a 24 volt system, the system voltage should be from 24.8 to 29.5 DCV. For a 32 volt system, the system voltage should be from 33.1 to 39.3 DCV.

Results:

• OK - The system voltage is correct. Proceed to test step 4.

• NOT OK - System voltage is NOT correct.

  Repair: For troubleshooting, see Testing And Adjusting, "CID 168 Electrical System".

  Stop.

Test Step 4. CHECK SETPOINT P01.

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

Expected Result:

Setpoint P01 should be programmed in order to match the type of fuel control solenoid which is used on the generator set.

Results:

• OK - Setpoint P01 is programmed correctly. Proceed to test step 5.

• NOT OK - Setpoint P01 is NOT programmed correctly.

  Repair: Reprogram setpoint P01. See Systems Operation, "Engine/Generator Programming OP5-0".

  Stop.

Test Step 5. CHECK FUSES.

1. Turn the ECS to OFF/RESET.

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

Expected Result:

None of the fuses are open.

Results:

• OK - None of the fuses are open. Proceed to test step 6.

• NOT OK - One or more of the fuses are open. Proceed to test step 7.

Test Step 6. CHECK VOLTAGE AT THE RELAY MODULE.

1. Fuse "F4" remains removed from the relay module.

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

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

4. 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 Step 3.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage that was previously measured in Step 3.A. There is an open circuit between RM-15 of the relay module and the fuel control solenoid.

  Repair: Repair the circuit. See the preceding System Schematic.

  Stop.

• NOT OK - The system voltage is lower than the voltage that was previously measured in Step 3.A. Proceed to test step 8.

Test Step 7. TROUBLESHOOT THE BLOWN FUSE.

This test step continues troubleshooting from test step 7. See the preceding System Schematics. Also, see Testing And Adjusting, "Schematics & 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 battery negative ("B-").

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

Expected Result:

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

Note: On some ETR fuel systems with a dual coil fuel control solenoid, the correct normal resistance can measure less than 1 ohm.

Results:

• OK - The resistance is greater than 3 ohms and the fuse is no longer blowing.

  Repair: Carefully check ALL wires that are connected to the appropriate terminal of the relay module. Check the wires for abrasion or worn spots in the insulation that could be causing the short. Check the wires in the panel, the generator panel, and on the engine harness. Refer to the various wiring diagrams as necessary. Repair the wiring or replace the wiring as necessary.

  Stop.

• NOT OK < 3 Ohms - If the resistance is less than 3 ohms, there is a short to the battery negative ("B-").

  Repair: Remove one component or one wire at a time that is in series with the load side of the fuse terminal. Remove the components or the wires until the failed component or wire is isolated. Repair the failed component or the wiring or replace the failed component or the wiring.

  Stop.

• NOT OK > 3 Ohms - If a resistance is greater than 3 ohms and the fuse still blows when all the wires are removed from the appropriate terminals, the relay module has failed.

  Repair: Replace the relay module.

  Stop.

Test Step 8. CHECK LOW VOLTAGE CONDITION.

This test step continues troubleshooting from test step 8. Fuse "F4" remains removed from the relay module. See Testing And Adjusting, "Schematics And Wiring Diagrams". Prepare to make voltage measurements at the relay module.

1. Turn the ECS to OFF/RESET. 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. The system voltage was measured previously in test step 3.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage. Proceed to test step 9.

• NOT OK - The voltage is NOT ± 2.0 DCV of the system voltage. The voltage is NOT correct.

  Repair: Check the wiring and recheck the fuse "F2". Repair the wiring or the components or replace the wiring or the components.

  Stop.

Test Step 9. CHECK FOR DIAGNOSTIC CODES

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 test step 10.

• NOT OK - A diagnostic code other than CID 566 FMI 7 is active.

  Repair: Correct the other diagnostic code. Proceed to the corresponding troubleshooting procedure.

  Stop.

Test Step 10. CHECK VOLTAGE AT THE RELAY MODULE.

1. Fuse "F4" remains removed from the relay module.

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

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

4. 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 Step 3.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage that was previously measured in Step 3.A. There is an open circuit between RM-15 of the relay module and the fuel control solenoid.

  Repair: Repair the wiring. See Testing And Adjusting, "Schematics & Wiring Diagrams".

  Stop.

• NOT OK - The system voltage is lower than the voltage that was previously measured in Step 3.A.

  Repair: Replace the relay module. See Testing And Adjusting, "Relay Module - Replace".

  Stop.

Test Step 11. CHECK VOLTAGE AT THE AIR SHUTOFF SOLENOID.

This test step continues troubleshooting from the test step 1 (initial check). Prepare to make a voltage measurement at the air shutoff solenoid. The 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. 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 - The voltage is from 0 to 2.0 DCV.

  Repair: Voltage is correct. If the air shutoff remains tripped or cannot be reset, the fault is in the air shutoff. Refer to the Service Manual for the engine.

  Stop.

• NOT OK - The voltage is NOT from 0 to 2.0 DCV. Proceed to test step 12.

Test Step 12. CHECK 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. 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.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage. 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.

  Repair: Repair the circuit. See Testing And Adjusting, "Schematics And Wiring Diagrams".

  Stop.

• NOT OK - The voltage is NOT ± 2.0 DCV of the system voltage. Proceed to test step 13.

Test Step 13. 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 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 that the air shutoff relay is shorted.

Expected Result:

The resistance should be greater than 10000 ohms.

Results:

• OK - The resistance is greater than 10000 ohms. Check for a short from +battery to RM-19 of the relay module.

  Repair: 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 is less than 10000 ohms. The short is internal to the relay module.

  Repair: Replace the relay module. See Testing And Adjusting, "Relay Module - Replace".

  Stop.