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

Illustration 1	g00798215

System Schematic For Fuel Control Relay On ETR Systems

The CID 0566 alerts the operator that the GSC+ did not control the engine shutdown. The GSC+ normally controls all engine shutdowns 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:

• The GSC+ detects a drop in engine speed from the rated speed to 0 RPM. The GSC+ has not called for a shutdown.

• The GSC+ determines that no engine speed sensor fault is present.

• The GSC+ will generate a CID 0566 FMI 07. The GSC+ will then disable the engine from running or starting.

Note: An unexpected shutdown fault (CID 0566) will initiate a signal to the shunt trip circuit breaker.

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 diagnostic code from the fault log after troubleshooting is complete.

Note: This procedure requires many voltage measurements during simulated engine cranking. Remove fuse "F4" which is the fuse for the starting motor. The fuse is located on the relay module. The fuse is removed in order to prevent activating the starting motor. Engine cranking does not occur. Voltage measurements must be made quickly before the total cycle crank time (setpoint P017) elapses. The total cycle crank time is 90 seconds. An overcrank fault will occur after 90 seconds. See Systems Operation, "Engine/Generator Programming OP5-0". 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.

Note: If the generator set is equipped with an electronic governor, also check the engine speed sensor. See the Troubleshooting, "CID 0190" sections of this manual.

Test Step 1. PERFORM AN INITIAL CHECK FOR OTHER ACTIVE DIAGNOSTIC CODES.

Note: Make sure that there are NO OTHER ACTIVE DIAGNOSTIC CODES. 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 make sure that there are NO OTHER ACTIVE DIAGNOSTIC CODES 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, the GSC+ 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.

1. Check the fuel level and quality.

2. Check for a plugged fuel filter.

3. Check for a plugged air filter.

Expected Result:

The previous checks are OK.

Results:

• OK - No problem was found after the previous checks were made. Proceed to test step 2.

• NOT OK - One or more problems are found after the previous checks are made.

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

  Stop.

Test Step 2. 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 3.

• NOT OK - System voltage is NOT correct.

  Repair: For troubleshooting, see Testing And Adjusting, "CID 0168 Electrical System".

  Stop.

Test Step 3. CHECK THE GOVERNOR AND CHECK THE 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. Turn the ECS to START.

4. Observe the governor and the fuel rack.

Expected Result:

The governor linkage and the fuel rack should move in the "fuel on" direction.

Results:

• OK - The fault is in the engine or the fuel system.

  Repair: Refer to the corresponding Engine Service Manual.

  Stop.

• NOT OK - The governor linkage and the fuel rack are not moving in the "fuel on" direction. Proceed to test step 4.

Test Step 4. CHECK SETPOINT P001.

1. Check setpoint P001 for proper programming. "0=ETR", "1=ETS". See Systems Operation, "Engine/Generator Setpoint Viewing OP2".

Expected Result:

Setpoint P001 should be programmed in order to match the type of fuel control solenoid which is used on the generator set."0=ETR", "1=ETS"

Results:

• OK - Setpoint P001 is programmed correctly. Proceed to test step 5.

• NOT OK - Setpoint P001 is NOT programmed correctly.

  Repair: Reprogram setpoint P001. See Systems Operation, "Engine/Generator Programming OP5-0".

  Stop.

Test Step 5. CHECK VOLTAGE AT THE FUEL CONTROL SOLENOID.

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

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

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

4. At the fuel control solenoid, measure the voltage across the terminals.

Expected Result:

The voltage should be ± 2.0 DCV of the system voltage which was measured in test step "2A".

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage which was measured in test step "2A". The fault is with the governor or the fuel rack. Refer to the appropriate Service Manual for generator sets that are not equipped with an electronic governor. Proceed to test step 12, if the generator set is equipped with an electronic governor.

• NOT OK - The voltage is low. Proceed to test step 6.

Test Step 6. 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 7.

• NOT OK - One or more of the fuses are open. Proceed to test step 8.

Test Step 7. 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 2.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage that was previously measured in Step 2.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 2.A. Proceed to test step 9.

Test Step 8. 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 circuit that contains a fuse that is blown, the circuit resistance should be less than 3 ohms.

Note: On some ETR fuel systems with a fuel control solenoid (dual coil), 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 following places: panel, generator panel and engine harness. Refer to the various wiring diagrams, if necessary. Repair the wiring or replace the wiring, if 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 - All of the components and wires have been removed. The fuse continues to open. If the resistance is greater than 3 ohms, the relay module has failed.

  Repair: Replace the relay module.

  Stop.

Test Step 9. 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 2.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage. Proceed to test step 10.

• 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 10. 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 0566 FMI 07 is active.

Results:

• OK - OnlyCID 0566 FMI 07 is active. Proceed to test step 11.

• NOT OK - A different diagnostic code is active.

  Repair: Correct the other fault. Proceed to the corresponding troubleshooting procedure.

  Stop.

Test Step 11. 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 2.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage that was previously measured in Step 2.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 2.A.

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

  Stop.

Test Step 12. CHECK SUPPLY VOLTAGE OF ELECTRONIC GOVERNOR.

This test step continues troubleshooting from test step 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. Turn the ECS to START.

2. Measure the voltage from the positive terminal of the electronic governor to the negative terminal of the electronic governor.

Expected Result:

The voltage should be ± 2.0 DCV of the system voltage. The system voltage was previously measured in test step 2.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage that was previously recorded. The supply voltage is correct. The fault is in the electronic governor or the actuator system.

  Repair: Repair the electronic governor or the actuator system. For the 8290 electronic governor, refer to the Service Manual Module, SENR6565. For the 524 electric governor system and the 1724 electric governor systems, refer to the Service Manual Module, SENR6430.

  Stop.

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

Test Step 13. CHECK FUSE "F2"

1. Verify that fuse "F2" is not open.

Expected Result:

The fuse "F2" is NOT open.

Results:

• OK - The fuse "F2" is NOT open. Proceed to test step 15.

• NOT OK - The fuse "F2" is open. Proceed to test step 14.

Test Step 14. TROUBLESHOOT THE BLOWN FUSE.

This test step continues troubleshooting from test step 14. 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 circuit that contains a fuse that is blown, the circuit resistance should be less than 3 ohms.

Note: On some ETR fuel systems with a fuel control solenoid (dual coil), 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 following places: panel, generator panel and engine harness. Refer to the various wiring diagrams, if necessary. Repair the wiring or replace the wiring, if necessary.

  Stop.

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

  Repair: Remove one component or 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 wiring or replace the failed component or wiring.

  Stop.

• NOT OK > 3 Ohms - All of the components and wires have been removed. If the resistance is greater than 3 ohms, the relay module has failed.

  Repair: Replace the relay module.

  Stop.

Test Step 15. 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 2.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage that was previously measured in Step 2.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 2.A. Proceed to test step 16.

Test Step 16. 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 2.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage. Proceed to test step 17.

• 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 17. 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 0566 FMI 07 is active.

Results:

• OK - Only CID 0566 FMI 07 is active. Proceed to test step 18.

• NOT OK - A different diagnostic code is active.

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

  Stop.

Test Step 18. 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 2.A.

Results:

• OK - The voltage is ± 2.0 DCV of the system voltage that was previously measured in Step 2.A. There is an open circuit between RM-15 of the relay module and the fuel control solenoid. Check the slave relay, the fuel control relays (1FCR and 2FCR) and the wiring.

  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 2.A.

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

  Stop.