ELECTRONIC MODULAR CONTROL PANEL (SR-4 GENERATOR MOUNTED) Caterpillar


Service Procedures

Usage:

Service Procedure A (Programming The ECM)

The set points programmed into the ECM are factory set. They can be changed to conform to the appropriate specifications when the ECM is moved from one engine type to another or when a special setting (usually overcrank or cycle crank) is needed. Install a security seal on the access cover to prevent unauthorized tampering. Do not open this cover in a humid environment and replace cover as soon as possible. A continuous bead of 6V6640 Sealant must be used to reseal this cover against humidity.

NOTE: Always check print 9Y1400 that is with the generator set for correct setpoints.

Programability


Location Of Cover
(1) Cover.

Setpoint information is stored then used in the control strategy of the ECM. To program, shutdown the engine, remove access cover (1) on the backside of the ECM. A potentiometer (2) rotary switch (3) and momentary switch (4) will be visible. Note the position of rotary switch (3). Turn rotary switch (3) to the position that corresponds to the setpoint to be adjusted. The LCD display will now read the position of the rotary switch and the data stored at that location. Press momentary switch (4). The data information corresponding to the position of the potentiometer will flash. Adjust potentiometer (2) to change the flashing data as desired. Once the data is correct, press momentary switch (4). The data information should stop flashing. Reprogramming of the setpoint is now complete. Return the rotary switch to position 0 if the system has an energize to run fuel solenoid or position 1 if the system has an energize to stop or latching fuel solenoid. The engine will not run when in the program mode or if the position of the rotary switch does not correspond to the operating mode programmed into setpoint 02. Consult Caterpillar Inc. concerning alterations to setpoints that have been specified for your engine.


Component Location
(2) Potentiometer. (3) Rotary switch. (4) Momentary switch.

Setpoints

02 ETR/ETS And Latching: This setpoint value will describe the operating mode of the ECM.

0 or 2 programs the ECM to operate with an energize to run (ETR) fuel solenoid.

1 or 3 programs the ECM to operate with an energize to shutdown (ETS) or latching fuel solenoid.

2 or 3 programs the ECM to ignore faults that could be caused by the transducer (sensor) module, i.e., high coolant temperature, low oil pressure and sensor module malfunction will not shut down the engine.

03 Metric/English: A setpoint value of 0 will command the ECM to display engine parameters in English. A setpoint value of 1 will display metric. See table that follows:

04 Ring Gear Teeth: This setpoint value must be same as the number of teeth on the ring gear. Range 95 to 350.

05 & 06 Overspeed: Program one of these positions to the desired engine speed at which an overspeed shutdown should occur. Position 05 has a range of 400 to 2950 rpm. Position 06 has a range of 2450 to 5000 rpm in increments of 10 rpm.

07 Crank Termination Speed: Once the engine speed passes this setpoint, the starter will no longer be energized. Range is 100 to 1000 rpm in increments of 10 rpm.

08 Oil Step Speed: Once the engine speed increases past this setpoint, the ECM will consider the engine to be above the low idle condition in regard to low oil pressure shutdown and alarm. Range is 400 to 1800 rpm in increments of 10 rpm.

09 Rated Oil Pressure Shutdown: If the engine lube pressure drops below the setpoint and the engine speed has been above the oil step speed for 9 seconds, the ECM will enter a low oil pressure shutdown condition. Range is 35 to 420 kPa (5 to 60 psi). Alarm signal sent to annunciator module occurs at 35 kPa (5 psi) above the shutdown.

10 Idle Oil Pressure Shutdown: If the engine lube pressure drops below this setpoint and the engine has been running for more than 9 seconds, the ECM will enter a low oil pressure shutdown condition. Range is 20 to 345 kPa (3 to 50 psi). The alarm signal sent to annunciator module occurs at 35 kPa (5 psi) above the shutdown.

11 High Coolant Temperature Shutdown: If the engine coolant temperature has been past the setpoint for 10 seconds. The ECM will enter a high coolant temperature shutdown condition. Range is 95 to 120°C (203 to 248°F). Alarm signal sent to annunciator module occurs at 6°C (11°F) below the shutdown temperature.

12 Low Coolant Temperature Alarm: If the engine coolant temperature has been below this setpoint for two seconds, the ECM will send an alarm signal to the annunciator module. Range is 10 to 30°C (50 to 86°F). Factory set at 21°C (70°F).

13 Overcrank Time: Total time to start the engine (from when first asked to start until overcrank is indicated). Range is 5 to 120 seconds. Factory setting is 90 seconds.

14 Cycle Crank: The amount of time the engine starter will crank. Also, the amount of time the starter will rest during a cycle crank. Range is 1 to 60 seconds. Factory setting is 10 seconds.

15 Cooldown: The amount of time the engine will run after it has been told to stop during a normal shutdown. Range is 0 to 30 minutes. Factory set at 15 minutes.

Engine Speed Setpoint Chart (In RPM)

Service Procedure B (Relay Module)

The relay module is the housing that contains the fuses and terminals 16-27 and is part of the back of the ECM.

1. Disconnect wire from terminal 1 in generator. Check to be sure there is no voltage on the B+ terminal of the ECM. Some of the harness may need to be removed for easy accessibility. Since moisture can be introduced into the ECM when the relay housing is removed, it is important to do this in a fairly dry environment. Open this housing in an air conditioned area if relative humidity exceeds 60%.


Location Relay Housing (Typical Example)
(1) Relay housing. (2) Screws.

2. Remove screws (2) and washers that hold relay housing (1) to main housing. To open housing, insert a thin knife blade between the relay housing and main housing. Drive it into the gap by tapping gently to break seal loose.

3. Open the housing and locate the relay or relays that need changed. Relays are labeled K1 through K7 on the PC board.


Relay Locations (Typical Example)
(3) K7 - fuel control (FCR). (4) K6 - air shutoff (ASR). (5) K1 - 2301 Ramp (2301). (6) K5 - (RR). (7) K2 - fault shutdown (ENFR). (8) K4 - starting motor (SMR). (9) K3 - crank termination (CTR).

4. Remove the relay clip and pull the relay straight out.

5. Do Relay Performance Test:

Check continuity with ohmmeter as follows:

A. With no power on terminals 7 and 8, there should be 1 ohm or less between terminals 1 and 5. There should also be 1 ohm or less between terminals 2 and 6. Coil resistance between terminals 7 and 8 should be 140 to 180 ohms.

B. Apply 12 volts DC to terminals 7 and 8. Now there should be 1 ohm or less between terminals 3 and 5. There also should be 1 ohm or less between terminals 4 and 6. There should be 100k ohm or more resistance between any other pairs of terminals.

6. Replace the relay if it fails this test and put the clip back on.

7. Check the connector going from the main housing to the relay PC board to assure that it is still inserted properly.

8. If replacing the relay does not fix problem or if the relay is not defective, replace the entire relay module.

9. Clean and apply primer (6V1541) to both housings' sealing surface.

10. Apply a continuous bead of sealant (6V6640) to the main housing sealing surface.

11. Install relay housing (1) on the main housing and fasten with original washers and screws (2).

12. Reconnect the wires that were removed.

Service Procedure C (Programming The ACM)

The AC meter module (ACM) is factory set to display AC voltages and AC currents as specified by the customer. If the current transformers (CTs) are replaced with CTs having another ratio or if the generator is reconnected for a different voltage, the ACM must be reprogrammed.

If the generator set is a rental unit that is frequently reconnected from high to low voltage, use the CTs needed for the high current connection and set the voltage range for the highest voltage expected. This will avoid reprogramming the ACM every time the generator is reconnected.


Location Of Cover
(1) Cover.

The ACM can be programmed using two 16 position switches, S2 (2) for voltage and S1 (3) for current, to accommodate various voltmeter ranges and CT ratios. These switches are located under the access cover (1) in the rear of the ACM. The charts show the switch positions that correspond to the different voltmeter ranges and current transformer (CT) ratios used.


Location Of Switches (Typical Example)
(2) S2 switch. (3) S1 switch. (4) R6.

Since moisture can be introduced into the ACM when the access cover is removed, it is important to do this in a fairly dry environment. Open this cover in an air conditioned area if relative humidity exceeds 60%. The ACM can be removed from panel for programming.

To program, remove cover and turn S1 and S2 to the positions indicated in the table. Be sure that the external jumper is also connected to the terminals indicated in the table. Do not adjust the two calibration potentiometers to the right of S1 and S2. These are factory set to calibrate the ACM against an accurate standard. When paralleling two generator sets, the voltage readings may not quite agree. In this case the upper potentiometer R6(4) can be adjusted so that both voltage displays read the same.

After programming the ACM, replace cover (1). A continuous bead of 6V6640 Sealant must be used to seal the cover.

Service Procedure D Alarm Module (DC Voltage Alarm Setpoint Adj.)


Location Of Plug (Typical Example)
(1) Plug.

For all alarm applications, the low DC volts alarm setpoint is adjusted by means of a potentiometer located under an access plug (1) on the rear of the module. The adjustment range is 8 to 38 volts. To adjust the low DCV alarm setpoint:

1. Remove plug (1) which covers the adjustment pot on the rear of the annunciator module.

2. Disconnect wires on terminals 1 and 7. Connect a variable DC power supply to the annunciator module (+ voltage to terminal 1, - voltage to terminal 7). Set the power supply voltage to the desired low DCV alarm setpoint. (Must be between 8 and 38 volts.)

3. Turn the adjustment pot fully counterclockwise.

4. After one minute, the low DC volts LED will flash. Press the acknowledge/silence switch to get a steady low voltage light.

5. Turn the adjustment pot clockwise slowly until the LED goes out.

6. Replace the plug. Since moisture can be introduced into the ALM when the plug is removed, it is important to do this in a fairly dry environment. Remove this plug in an air conditioned area if relative humidity exceeds 60%.

7. Disconnect the variable DC power supply and connect wires removed in Step 2.

Service Procedure E (Magnetic Switch Test - 24V)


Location Of Magnetic Switch

1. Disconnect jumper wire between terminals 4 and 5 in the generator mounted terminal strip (TS1). Measure resistance between terminal 5 and terminal 2. Resistance should be 26 to 33 ohms. If resistance is incorrect, replace the defective magnetic switch. If OK, go to step 2.

2. Disconnect cable going from the pinion solenoid to the starter motor.

3. Connect a DC voltmeter: positive to terminal 24 and negative to terminal 25 in generator mounted terminal strip (TS1).

4. Connect a wire from terminal 1 to terminal 5 on generator mounted terminal strip (TS1). The voltmeter reading should go from approximately 24 VDC to approximately 2 VDC. If voltage exceeds 2 volts, replace magnetic switch. Disconnect this wire as soon as you get voltage measurement (no more than 10 seconds).

5. If the switch passes the requirements of Step 1 and 4, it is OK. Reconnect wires and cables that were removed in this procedure.

Service Procedure F (Speed Sensor ADJ.)


Magnetic Pickup
(1) Clearance dimension. (2) Locknut.

1. Remove the magnetic pickup from the engine flywheel housing and turn the flywheel until a gear tooth is directly in the center of the threaded opening for the magnet pickup. Install the magnetic pickup again in the threads of the flywheel housing.

2. Turn (by hand) in a clockwise direction until the end of the magnetic pickup just makes contact with the gear tooth. Now turn the magnetic pickup back out 1/2turn (180° in the counterclockwise direction) to get the correct air gap [clearance dimension (1)]. Now tighten locknut (2) to a torque of 45 ± 7 N·m (33 ± 5 lb.ft.).

NOTE: Do not let the magnetic pickup turn while locknut (2) is tightened.

Service Procedure G (Temp. Probe Resistance)


Components (Typical Example)
(1) Connector. (2) Transducer (sensor). (3) Temperature probe.

Measure the resistance of this probe (3) at room temperature using the 6V7070 multimeter. Disconnect connector (1). Be sure to make good connections to the probe connector pins. If the resistance does not agree with the following table, check connector on temperature probe and repair any bad connections. If connector is OK, replace temperature probe (3).

If temperature probe resistance is OK, check connector from oil pressure/temperature transducer (sensor) to temperature probe. If connector is OK, replace oil pressure/temperature transducer (2).

Schematics and Wiring Diagrams


AC Schematic (JIC)


AC Schematic (JIC) With Voltage Regulator Series Boost Option


DC Schematic (JIC)


DC Schematic (JIC)


Customer/Contractor Wiring Diagram

Caterpillar Information System:

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