Electronic Modular Control Panel II+ (EMCP II+) Caterpillar

The starting motor remains engaged after the engine has started.

Illustration 1	g00793846
Schematic For Starting Motor Relay (SMR) On "PEEC" Engines

Illustration 2	g00793852
Schematic For Starting Motor Relay (SMR) On "EUI" Engines

Test Step 1. CHECK THE SETPOINTS.

This test step checks the following setpoints: P011 (crank terminate speed), P017 (total cycle crank time) and P018 (cycle crank time).

1. View the setpoints and make a note of setpoints P011, P017 and P018. See Systems Operation, "Engine/Generator Setpoint Viewing OP2-0".

2. Compare the setpoints with the specified setpoints of the particular generator set. The default value for P011 is 400 rpm. The default value for P017 is 90 seconds. The default value for P018 is 10 seconds.

Note: Engines that are equipped with prelube pumps may require cycle crank times (setpoint P018) of 30 seconds or more.

Expected Result:

The setpoint value that is being viewed should match the specified setpoint value.

Results:

• OK - The setpoint is correct. Proceed to test step 2.

• NOT OK - The setpoint that is being viewed does not agree with the specified setpoint.

  Repair: Reprogram setpoints P011, P017 and P018. See Systems Operation, "Engine/Generator Programming OP5-0".

  Stop.

Test Step 2. CHECK THE START FUNCTION OF THE ENGINE.

The following procedure will require checks to be made during simulated engine starting. Disable the fuel system.

1. Disable the fuel shutoff solenoid or the PEEC in order to prevent the engine from starting but not from cranking. To disable the ECM on an EUI engine, remove the J1-40 connector.

2. Prepare to manually stop the engine from cranking, if necessary. Turn the battery disconnect switch to the OFF position or shut the engine off by using mechanical means.

3. Turn the engine control switch (ECS) to the START position. Allow the engine to crank.

4. Turn the ECS to the OFF/RESET position.

Expected Result:

The engine should stop cranking.

Results:

• OK - The engine does not crank. Proceed to test step 6.

• NOT OK - The engine continues to crank. Proceed to test step 3.

Test Step 3. CHECK THE START FUNCTION OF THE ENGINE.

1. The conditions of the previous step remain. The fuel system is disabled. The engine is cranking.

2. While the engine is still cranking, push the emergency stop push button.

Expected Result:

The engine should stop cranking.

Results:

• YES - The engine does not crank.

  Repair: Check the wire on "RM-18" of the relay module for a short to +battery. Repair the short or replace the harness. If a short is not found, replace the relay module. See Testing And Adjusting, "Relay Module - Replace".

  Stop.

• NO - The engine continues to crank. Proceed to test step 4.

Test Step 4. CHECK THE START FUNCTION OF THE ENGINE.

1. The conditions of the previous step remain. The fuel system is disabled. The engine is cranking.

2. Stop the engine. Turn the battery disconnect switch to the OFF or shut the engine off by using mechanical means.

3. Remove all wires from the output terminal of the starting motor magnetic switch (SMMS) in the junction box.

4. Turn the ECS to START. Attempt to crank the engine.

Expected Result:

The engine should not crank.

Results:

• OK - The engine does not crank.

  Repair: The "SMMS" or related wiring has failed. Troubleshoot the "SMMS" and the related wiring. See the Generator Set Wiring Diagram in Testing And Adjusting, "Schematics & Wiring Diagrams".

  Stop.

• NOT OK - The engine continues to crank. Proceed to test step 5.

Test Step 5. CHECK THE START FUNCTION OF THE ENGINE.

1. The conditions of the previous step remain. The fuel system is disabled. The engine is cranking.

2. Stop the engine. Turn the battery disconnect switch to OFF or shut the engine off by using mechanical means.

3. Disconnect the "B+" wire on the pinion solenoid of the starting motor.

4. Turn the ECS to START and attempt to crank the engine.

Expected Result:

The engine should not crank.

Results:

• OK - The engine does not crank.

  Repair: On 3412 and 3456 engines, wire 25-RD in the engine harness is shorted to the battery. Troubleshoot the wiring. See the Generator Set Wiring Diagram in Testing And Adjusting, "Schematics And Wiring Diagrams".

  Stop.

• NOT OK - The engine continues to crank.

  Repair: The starting motor has failed. Troubleshoot the starting motor. Refer to the Starting Motor and/or Engine Service Manuals.

  Stop.

Test Step 6. CHECK THE STARTING MOTOR CYCLING.

1. The fuel delivery is disabled.

2. Turn the ECS to the START position.

Expected Result:

The starting motor should cycle on and off according to setpoint P018 (cycle crank time).

Results:

• OK - If the starting motor cycles correctly, the problem is not present. Stop.

• NOT OK - If the starting motor remains engaged, the starting motor has failed.

  Repair: Troubleshoot the starting motor. Refer to the Starting Motor and/or Engine Service Manuals.

  Stop.