Electronic Modular Control Panel II+ Paralleling (EMCP II+P) 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	g01447141

The EMCP II+P monitors the battery voltage in order to protect the EMCP II+P from a battery problem or from a charging problem. The battery voltage is received from the engine ECM by the CAT data link. If you receive a CID 168 E fault, refer to Troubleshooting, RENR9348 or Systems Operation Testing and adjusting, RENR9968 for C32 Generator Set Engines. The GSC+P treats a CID 168 fault as an alarm fault. The threshold for a CID 168 FMI 03 fault for battery voltage is greater than 32 DCV for 24 volt system. The threshold for a CID 168 FMI 03 fault for battery voltage is greater than 45 DCV for a 32 volt system.

The setpoint for the system voltage (P007) specifies the battery voltage.

24 - 24 Volt System

32 - 32 Volt System

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+P for an MUI engine. This eliminates the engine ECM as a possibility of the fault. For more information, refer to System Operation, "Protective Relaying Programming OP5-1".

• Temporarily remove the Off Reset Relay (ORR) from the relay panel.

• Temporarily remove jumper wire on GSC+P relay module between terminal 1 and 2.

• Begin the Test procedure.

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 DC CONNECTOR TERMINALS AND THE BATTERY VOLTAGE.

1. Turn the ECS to the STOP position.

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

3. Measure the voltage between BATT+ and BATT-. Take note of the voltage.

4. Compare the voltage measured at the battery with the voltage measured between the DC connector terminals.

Expected Result:

The voltage measured at the battery and the voltage measured between the DC connector terminals should be within 2.0 DCV.

Results:

• OK - The voltage measured at the battery and the voltage measured between the DC connector 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 DC connector 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 DC CONNECTOR TERMINALS AND THE ECS.

1. Turn the ECS to the STOP position.

2. Measure the voltage between "BATT+" and "BATT-". Take note of the voltage.

3. Measure the voltage between GSC-RM2 and "BATT-". Take note of the voltage.

4. Compare the voltage that was measured between the "BATT+" and "BATT-" terminals with the voltage that was measured between the GSC-RM2 and "BATT-" terminals.

Expected Result:

The voltage that was measured between the "BATT+" and "BATT-" terminals and the voltage that was measured measured between the GSC-RM2 and "BATT-" terminals are within 2.0 DCV of each other.

Results:

• OK - The voltage that was measured between the "BATT+" and "BATT-" terminals and the voltage that was measured measured between the GSC-RM2 and "BATT-" terminals are within 2.0 DCV of each other. Proceed to Test Step 4.

• NOT OK - The voltage that was measured between the "BATT+" and "BATT-" terminals and the voltage that was measured measured between the GSC-RM2 and "BATT-" 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 4. CHECK THE CONTINUITY OF THE ECS.

1. If applicable, disconnect the jumper from terminal 6 to terminal 9 on the ECS.

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

3. Place the 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 Table 2.

Expected Result:

The measured resistances match Table 2.

Results:

• OK - The measured resistances match the Table. Proceed to Test Step 5.

• NOT OK - The measured resistances match the Table. The ECS has failed. 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 at contact 10 of the ECS. Take note of the voltage.

4. Compare the voltage measured between RM-1 and RM-28 with the voltage measured at contact 10.

Expected Result:

The voltages are within 2.0 DCV of each other.

Results:

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

• NOT OK - The voltages are not within two volts of each other.

  Repair: The wiring harness is faulty. 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 two voltages.

Expected Result:

The voltages are within 2.0 VDC of each other.

Results:

• OK - The voltages are within 2.0 VDC of each other. The fault is probably an intermittent fault which is caused by a faulty connector. Inspect the electrical connectors.

  Repair: Refer to Testing and Adjusting, "Electrical Connector - Inspect". If the faulty connector can not be found, repeat this test procedure. If the fault still remains, replace the GSC+P.

  STOP

• NOT OK - The voltages are not within 2.0 VDC of each other.

  Repair: Replace the GSC+P.

  STOP

Test Step 7. Reprogram the GSC+P.

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 terminal 6 and terminal 9. Not all generators will have a jumper wire between terminal 6 and terminal 9.

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

5. Replace the OFF RESET RELAY (ORR). Replace the jumper wire on the GSC+P relay module between terminal 1 and 2.

Expected Result:

Setpoint P023 should be programmed to the correct setting. The diagnostic code should no longer be present.

Results:

• OK - Setpoint P023 is programmed to the correct setting. The diagnostic code is no longer present.STOP

• NOT OK - Setpoint P023 is not programmed to the correct setting. The diagnostic code is still present.

  Repair: Reprogram the GSC+P. Refer to System Operation, "Engine Generator Programming OP5-0".

  STOP