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Product: GAS ENGINE

Model: G3612 GAS ENGINE BKE
Configuration: G3612 GENERATOR AND INDUSTRIAL BKE00001-UP
Troubleshooting
G3600 Engines
Media Number -RENR5910-06 Publication Date -10/01/2010 Date Updated -10/12/2010
i02889493
Electrical Power Supply - Test

SMCS - 1401-038
System Operation Description:
Use this procedure to troubleshoot the electrical system if one of the diagnostic or event codes in Table 1 is
active or easily repeated.
Refer to Troubleshooting, "Event Codes" for information about event codes and the default trip points for
these codes. You must access the monitoring system on Caterpillar Electronic Technician (ET) in order to
view the current trip points for these codes.
Table 1
Diagnostic Codes Table
Code Conditions which Generate this Code System Response
E042(3) Low System The shutdown output is activated.
Voltage Shutdown The code is logged.
E043(1) Low System The voltage is less than the trip point and
Voltage Warning the delay time has expired. No other codes
for the system voltage are present. The alarm output is activated. The
E050(1) High code is logged.
System Voltage
Warning
168-2 Electrical The Electronic Control Module (ECM) has The code is logged. If battery
System Voltage : been powered for at least five seconds. The voltage is lost and the voltage does
Erratic, Intermittent, engine is running. not return, the ECM will not log
or Incorrect The battery voltage is less than 6 VDC for a this diagnostic code.
minimum of 0.060 seconds and the voltage The alarm output is activated.
returns to the normal range within 0.015 The intermittent problem may not
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seconds. There are three voltage readings of affect engine operation. However,
less than 6 VDC within seven seconds. the engine may experience speed
burps, intermittent shutdowns,
and/or complete shutdowns.
336-2 Engine The ECM detects an invalid combination of
Control Switch : the inputs from the engine control switch to The shutdown output is activated.
Erratic, Intermittent, the ECM. This indicates a problem with the The code is logged.
or Incorrect engine control switch.
Electrical power is supplied to the ECM, to the Integrated Combustion Sensing Module (ICSM), and to the
air/fuel pressure module. The cause of an intermittent power supply can occur on either the positive side or
on the negative side of the power supply.
The 24 VDC power supply for the ECM can be provided by a battery or by an electrical power supply. The
minimum requirement for the power supply is 22 VDC at 16 amperes. The 24 VDC power supply can be
connected to the terminal box or to the control panel. Route the power supply through a dedicated fuse or
through a dedicated circuit breaker.
The ECM input at terminal 70 of the P1 connector ("Switched +Battery") receives battery voltage from the
engine control switch when the switch is in the START position, in the STOP position, or in the AUTO
position. When the ECM detects battery voltage at this input, the ECM will power up. When battery voltage
is removed from this input, the ECM will power down after the engine has shut down.
The "168-02" diagnostic code indicates that the voltage of the power supply is intermittent or low while the
engine is running. If the supply voltage drops to zero and stays at zero, the ECM will not log this code. The
engine will shut down.
The "336-02" diagnostic code indicates that the ECM has detected a problem with the circuit for the engine
control switch.
Logged diagnostic codes provide a historical record. Before you begin this procedure, use Cat ET to print the
logged codes to a file.
This procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the
original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 1 g01438756
Schematic for the electrical power source for in-line engines
Schematic for the electrical power source for vee engines
Test Step 1. Inspect the Electrical Connectors and Wiring
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the
ECM OFF.
Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Terminal Box
(1) ECM connector J2/P2
(2) ECM connector J1/P1
(3) 16 amp circuit breaker
(4) Connectors J3/P3 for the customer's connector
(5) Connectors J4/P4 for the optional control panel (if equipped) or for a customer's connector
(6) J5/P5 connectors for the harness from the sensors
(7) J6/P6 connectors for the harness from the sensors
B. Disconnect the J1/P1 connectors. Verify that the connectors do not have damage, corrosion, or
moisture.
C. Check the torque of the allen head screws for each of the ECM connectors. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for the correct torque values.
D. Thoroughly inspect the following connections:
◦ Connectors for the circuit breaker
◦ Connectors for the 24 VDC power supply
◦ Connectors for the engine control switch
Terminal locations at the P1 ECM connector for the electrical supply on the in-line engines and the vee engines
(P1-52) +24 VDC
(P1-53) +24 VDC
(P1-55) +24 VDC
(P1-57) +24 VDC
(P1-63) −Battery
(P1-65) −Battery
(P1-67) −Battery
(P1-69) −Battery
(P1-70) Keyswitch
a. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power
supply:
◾ Unswitched +Battery terminals 52, 53, 55, and 57
◾ −Battery terminals 63, 65, 67, and 69
◾ Switched +Battery terminal 70
b. Check the harness and wiring for abrasion and for pinch points from the power supply to the
ECM and from the engine control switch to the ECM.
Expected Result:
All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
Results:
• OK - All connectors, pins, and sockets are connected properly. The connectors and the wiring do not
have corrosion, abrasion, or pinch points. The components are in good condition with proper
connections. Proceed to Test Step 2.
• Not OK - At least one of the connectors, pins, or sockets is not connected properly. At least one
connector or wire has corrosion, abrasion, and/or pinch points. The components are not in good
condition and/or at least one connection is improper.
Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals
are properly installed. Make sure that the connectors are properly fastened. Verify that the repair has
eliminated the problem.
STOP
Test Step 2. Check the Voltage at the Power Supply and at the ECM
A. Make sure that the engine will not crank during this procedure. Make sure that the pressurized air
supply is OFF. Make sure that the air is purged from the system.
Note: If a power supply is used instead of batteries, the minimum voltage for the power supply is 22
VDC at 16 amperes.
B. Measure the voltage at the terminals for the power supply. Record the voltage.
C. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe
into terminal 52. Insert the second probe into terminal 63. Connect a multimeter to the probes.
G3612 GENERATOR AND INDUSTRIAL BKE00001-UP(SEBP3794 - 97) - Docu... Página 10 de 12
D. Switch the 16 amp circuit breaker for the ECM ON.
E. Measure the power supply voltage at the P1 connector. During the measurement, wiggle the harness in
order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections.
Expected Result:
The voltage that is measured at the terminals for the power supply is at least 22 VDC. The voltage that is
measured at the P1 connector is within 2 VDC of the voltage that was measured at the terminals for the
power supply. The voltage measurements are constant.
Results:
• OK - The ECM is receiving the correct voltage at the P1 connector.
Repair: Perform the following procedure:Switch the 16 amp circuit breaker for the ECM
OFF.Remove the probes from connector P1.
Proceed to Test Step 3.
• Not OK - The ECM is not receiving the correct voltage at the P1 connector.
Repair: Perform the following procedure:
1. Switch the 16 amp circuit breaker for the ECM OFF.
2. Remove the probes from connector P1.
3. Use a voltmeter to check the wiring. Check for an open circuit or for a short circuit in the wiring
harness. Refer to the appropriate schematic for the electrical system. Locate the source of the
voltage drop.
4. Make repairs, as needed.
STOP
Test Step 3. Check the Engine Control Switch
B. Connect Cat ET to the service tool connector.
C. Switch the 16 amp circuit breaker for the ECM ON.
Note: An "E225 Engine Overcrank" and/or an "E233 Low Engine Prelube Pressure" event code may
be generated during this step. After you have completed this step, clear the events from the "Logged
Events" screen of Cat ET.
D. Observe the "Active Diagnostic" screen on Cat ET and turn the engine control switch to the STOP
position, to the START position, and to the AUTO position. Look for an active "336-02 Incorrect ECS
Switch inputs" diagnostic code. Repeat this step several times.
Expected Result:
A "336-02 Incorrect ECS Switch inputs" diagnostic code was not activated when the engine control switch
was turned to the STOP position, the START position, and the AUTO position.
Results:
• OK - A "336-02 Incorrect ECS Switch inputs" diagnostic code was not activated. The inputs to the
engine control switch are correct. The problem seems to be resolved.
Repair: The problem may be intermittent. Refer to Troubleshooting, "Electrical Connectors -

Inspect".
STOP
• Not OK - A "336-02 Incorrect ECS Switch inputs" diagnostic code was activated. The ECM has
detected an invalid pattern for the input to the engine control switch. Proceed to Test Step 4.
Test Step 4. Check the Circuit of the Engine Control Switch
B. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the
ECM OFF.
C. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe
into terminal 31. Insert the second probe into terminal 61. Connect a multimeter to the probes.
D. Switch the 16 amp circuit breaker for the ECM ON.
Note: An "E225 Engine Overcrank" and/or an "E233 Low Engine Prelube Pressure" event code may
be generated during the test. After you have completed the test, clear the events from the "Logged
Events" screen of Cat ET.
Note: During these measurements, wiggle the harness in order to check for an intermittent problem.
Be sure to wiggle the harness near each of the connections.
E. Turn the engine control switch to the STOP position and measure the voltage between terminal 31 and
terminal 61 of the P1 connector. The correct voltage measurement is less than one volt.
F. Remove the probe from terminal 61 and insert the probe into terminal 62.
G. Turn the engine control switch to the START position and measure the voltage between terminal 31
and terminal 62 of the P1 connector. The correct voltage measurement is less than one volt.
H. Remove the probe from terminal 62 and insert the probe into terminal 64.
I. Turn the engine control switch to the AUTO position and measure the voltage between terminal 31
and terminal 64 of the P1 connector. The correct voltage measurement is less than one volt.
J. Remove the probe from terminal 31 and insert the probe into terminal 69. Remove the probe from
terminal 64 and insert the probe into terminal 70.
K. Turn the engine control switch to the STOP position and measure the voltage between terminal 69 and
terminal 70 of the P1 connector. The correct voltage measurement is at least 20 VDC.
L. Turn the engine control switch to the START position and measure the voltage between terminal 69
and terminal 70 of the P1 connector. The correct voltage measurement is at least +20 VDC.
M. Turn the engine control switch to the AUTO position and measure the voltage between terminal 69
and terminal 70 of the P1 connector. The correct voltage measurement is at least +20 VDC.
Expected Result:
The voltage checks are within the specifications.
Results:
• OK - The voltage checks are within the specifications. Remove the probes from the P1 connector.
Start the engine and run the engine. If the original problem is not resolved, the ECM may have a
problem.
Repair: It is unlikely that the ECM has failed. Perform the following procedure:Temporarily install a
new ECM. Refer to Troubleshooting, "ECM - Replace".If the problem is resolved with the new ECM,
install the original ECM and verify that the problem returns. If the new ECM operates correctly and
the original ECM does not operate correctly, replace the ECM.
STOP
• Not OK - The P1 connector does not have the correct voltage.
Repair: Perform the following steps:
1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker
for the ECM OFF.
2. Disconnect the wires for the STOP, START, and AUTO positions from the engine control
switch.
3. Use an ohmmeter to check continuity across the contacts of the switch. Check the continuity of
the contacts in the open and in the closed positions. Turn the switch to each position in order to
check the contacts.
4. If the engine control switch is faulty, replace the switch. If the problem is not resolved, repair
the harness, when possible. Replace the harness, if necessary.
STOP
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G3612 GENERATOR AND INDUSTRIAL BKE00001-UP(SEBP3794 - 97) - Docume...

Product: GAS ENGINE

Electrical Power Supply - Test

System Operation Description:

Schematic for the electrical power source for in-line engines

Schematic for the electrical power source for vee engines

Test Step 1. Inspect the Electrical Connectors and Wiring

(1) ECM connector J2/P2

(2) ECM connector J1/P1

(3) 16 amp circuit breaker

(4) Connectors J3/P3 for the customer's connector

(6) J5/P5 connectors for the harness from the sensors

(7) J6/P6 connectors for the harness from the sensors

D. Thoroughly inspect the following connections:

◦ Connectors for the circuit breaker

◦ Connectors for the 24 VDC power supply

◦ Connectors for the engine control switch

(P1-52) +24 VDC

(P1-53) +24 VDC

(P1-55) +24 VDC

(P1-57) +24 VDC

◾ Unswitched +Battery terminals 52, 53, 55, and 57

◾ −Battery terminals 63, 65, 67, and 69

◾ Switched +Battery terminal 70

D. Switch the 16 amp circuit breaker for the ECM ON.

• OK - The ECM is receiving the correct voltage at the P1 connector.

Proceed to Test Step 3.

Repair: Perform the following procedure:

1. Switch the 16 amp circuit breaker for the ECM OFF.

2. Remove the probes from connector P1.

4. Make repairs, as needed.

Test Step 3. Check the Engine Control Switch

B. Connect Cat ET to the service tool connector.

C. Switch the 16 amp circuit breaker for the ECM ON.

Repair: The problem may be intermittent. Refer to Troubleshooting, "Electrical Connectors -

Test Step 4. Check the Circuit of the Engine Control Switch

D. Switch the 16 amp circuit breaker for the ECM ON.

The voltage checks are within the specifications.

• Not OK - The P1 connector does not have the correct voltage.

Repair: Perform the following steps:

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