Electronic Modular Control Panel II (EMCP II) Caterpillar

This diagnostic code is associated with an electrical system voltage that is above normal. The FMI 03 means that the engine electronic control module (ECM) has determined that the electrical system voltage is above normal.

Illustration 1	g00650545

The EMCP II monitors the battery voltage in order to protect the EMCP II from a battery problem or from a charging problem. The battery voltage is received from the engine electronic control module (ECM) by the CAT data link. If you receive a CID 168 E diagnostic code, refer to Troubleshooting, "RENR 2227 - 3406E and 3456 EPG Engines". The GSC treats a CID 168 FMI 03 as a diagnostic code. The threshold for an alarm is greater than 32 DCV. The threshold for a CID 168 FMI 03 for battery voltage is greater than 45 DCV for a 32 volt system.

The setpoint for the system voltage (P07) specifies the battery voltage.

24 - 24 Volt System

32 - 32 Volt System

Note: The GSC does not receive battery power when the ECS is in the OFF/RESET position. When contact 6 is connected to one of the contacts (8, 9, 10), the GSC receives battery power when the ECS is in the OFF/RESET position.

Before beginning this procedure, ensure that the following steps have been performed:

• VERIFY THE DIAGNOSTIC CODE.

• Make sure that the CID 168 FMI 03 is shown on the display.

• Enter service mode.

• Turn the ECS to the STOP position.

• Program setpoint P023 to 0. This programs the GSC for an MUI engine. This eliminates the engine control module (ECM) as a possibility of the fault. For more information, see System Operation, Protective Relaying Programming OP5.

• Turn the ECS to the OFF/RESET position. Disconnect the jumper wire on the ECS that is between pin 6 and pin 9. Not all generators will have a jumper wire between pin 6 and pin 9. Proceed to Step 1.

Test Step 1. CHECK THE SYSTEM'S VOLTAGE.

1. Turn the ECS to the STOP position.

2. Measure the voltage across the battery terminals.

Expected Result:

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

Results:

• OK - For a 24 volt system, the voltage is 24.8 DCV to 29.5 DCV. For a 32 volt system, the voltage is 33.1 DCV to 39.3 DCV. Proceed to Test Step 2.

• NOT OK - For 24 volt systems, the voltage is not between 24.8 DCV to 29.5 DCV. For a 32 volt system, the voltage is not between 33.1 DCV to 39.3 DCV. The problem is in the charging system.

  Repair: Proceed to Testing and Adjusting, "Charging System - Test".

  Stop.

Test Step 2. COMPARE THE VOLTAGE BETWEEN "TS1-1" AND THE BATTERY VOLTAGE.

1. Turn the ECS to the STOP position.

2. Measure the battery voltage across the terminals. Take note of the battery voltage.

3. Measure the voltage between "TS1-1" and "TS1-30". Take note of the voltage.

4. Compare the battery voltage that was measured with the voltage measured between "TS1-1" and "TS1-30".

Expected Result:

The voltage measured at the battery and the voltage measured between "TS1-1", "TS1-30" should be within 2.0 DCV. of each other.

Results:

• OK - The voltage measured at the battery and the voltage measured between the terminals are within 2.0 DCV of each other. Proceed to Test Step 3.

• NOT OK - The voltage measured at the battery and the voltage measured between the terminals are NOT within 2.0 DCV of each other. The wiring harness is not correct.

  Repair: Repair the wiring harness or replace the wiring harness.

  Proceed to Test Step 7.

Test Step 3. COMPARE THE VOLTAGE BETWEEN "TS1-1" AND THE ECS.

1. Turn the ECS to the STOP position.

2. Measure the voltage between "TS1-1" and "TS1-30". Take note of the voltage.

3. Measure the voltage at terminal "6" on the ECS. Take note of the voltage.

4. Compare the measured voltages.

Expected Result:

The voltage that was measured at the terminals and the voltage that was measured at the ECS are within 2.0 DCV of each other.

Results:

• OK - The voltage that was measured at the terminals and the voltage that was measured at the ECS are within 2.0 DCV of each other. Proceed to Test Step 4.

• NOT OK - The voltage that was measured at the terminals and the voltage that was measured at the ECS are NOT within 2.0 DCV of each other. The wiring harness is not correct.

  Repair: Repair the wiring harness or replace the wiring harness.

  Proceed to Test Step 7.

Test Step 4. CHECK THE CONTINUITY OF THE ECS .

1. Disconnect the jumper from" 6" to jumper "9" from the ECS. Not all generators will have a jumper wire between Pin" 6" and Pin" 9".

2. Place the ECS in the "OFF/RESET" position.

3. Place one lead on terminal "6" of the ECS.

4. Measure the resistance from terminal "6 "to each of the terminals (7, 8, 9, and 10).

5. Use the same procedure for each switch position.

6. Compare the measured resistances with the table above.

Expected Result:

The measured resistances match the table above.

Results:

• OK - The measured resistances match the table above.

  Repair: The ECS is not faulty.

  Proceed to Test Step 5.

• NOT OK - The measured resistances do not match the table above. The ECS is faulty.

  Repair: Replace the ECS. Reinstall the jumper wire.

  Proceed to Test Step 7.

Test Step 5. Compare the voltage between "RM-1 "and the ECS.

1. Turn the ECS to the STOP position.

2. Check the voltage between" RM-1" and "RM-28". Take note of the voltage.

3. Check the voltage on contact "10" of the ECS. Take note of the voltage.

4. Compare the two voltages.

Expected Result:

The measured voltages are within 2.0 DCV of each other.

Results:

• OK - The measured voltages are within 2.0 DCV of each other. The harness is correct. Proceed to Test Step 6.

• NOT OK - The measured voltages are not equal to 2.0 DCV. The wiring harness is faulty.

  Repair: Repair the harness or replace the harness.

  Proceed to Test Step 7.

Test Step 6. COMPARE THE VOLTAGE BETWEEN RM-1 AND THE LOWER DISPLAY.

1. Turn the ECS to the STOP position.

2. Check the voltage between "RM-1" and "RM-28". Take note of the voltage.

3. Check the voltage that is shown on the lower display. Take note of the voltage.

4. Compare the voltage measurements.

Expected Result:

The voltage that was measured between "RM-1" and "RM-28" should be within 2.0 DCV of the voltage that was measured on the lower display.

Results:

• OK - The voltage that was measured between "RM-1" and "RM-28" is within 2 DCV of the voltage that was measured on the lower display.

  Repair: The problem is probably an intermittent failure that was caused by a failed connector. Inspect the electrical connectors. Refer to Testing and Adjusting, "Electrical Connector - Inspect". If the failed connector can not be found, repeat this test procedure. If the fault still remains, replace the GSC.

  Stop.

• NOT OK - The voltage that was measured between "RM-1" and "RM-28" is NOT within 2.0 DCV of the voltage that was measured on the lower display. The GSC has failed.

  Repair: The GSC may have failed. Replace the GSC.

  Stop.

Test Step 7. Reprogram the GSC.

1. Turn the ECS to the STOP position.

2. Program the setpoint P023 to 2 (EUI). Refer to System Operation, "Engine Generator Programming OP5-0".

3. Turn the ECS to the OFF/RESET position. If applicable, disconnect the jumper wire on the ECS that is between pin "6" and pin "9". Not all generators will have a jumper wire between pin "6" and pin "9".

4. Verify that the diagnostic code is no longer present.

5. Replace the jumper between pin 6 and pin 9. Not all generators will have a jumper wire between pin 6 and pin 9.

Results:

• The system operates normally. - Stop.