Caterpillar — Procedure (30 steps)

A Caterpillar service procedure — check it applies to your exact model before use.

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Procedure

1. 5. Select All State. Characters “1” through “12” should now be flashing. This state allows the operator to select all the changes that will be programmed. This state also allows the operator to disregard the previous changes. The upper display will flash until the “SELECT” button is pushed in order to accept previous selections. The upper display will flash until the “LEFT” and “RIGHT” button is pushed in order to reject the previous selections. If the “SELECT” button is pushed, the display stops flashing for two seconds in order to show that the selections have been programmed successfully into the
2. 1. PRCM. The program returns to in order to allow the user to continue programming the remaining outputs and inputs. If the “LEFT” and “RIGHT” button is pushed, the
3. 1. program returns immediately to , but the previous selections are NOT programmed into the PRCM. 18 Systems Operation Section g00711864 Illustration 24 PRCM Displays After Programming
4. 6. Press the “ENTER” button in order to exit the programming mode. The following illustration represents an inactive input and output. When the ECM detects a low specific alarm range the data for this condition is sent to the PRCM via the CAT data link. The PRCM will display characters “5” through “8” as being active. The “K1” symbol will be shown on the lower display to show that this relay is activated. The normally open contacts will close. The device that is connected to the output will activate. g00711875 Illustration 25 ECM) In another example, the PRCM input and output has been programmed to activate alarm “1” whenever switch input 1 is inactive. The top LED display will be activated. Characters “5” and “6” show that the output is active. Characters “7” and “8” show that the input is inactive. The colon between characters “6” and “7” indicates that the output state is inverted from the input state. g00711922 Illustration 26 PRCM Displays With Inactive Input (Switch Input 1) 19 Systems Operation Section RDM is present. The operator should record the programming of the inputs and outputs for future reference. This will aid the operator if the activation of one of these outputs requires troubleshooting. AUTO Input And Output Scroll The AUTO input and output Scrolling mode screen will be displayed when the “LEFT” and “RIGHT” scroll through each of the selected AUTOSCROLL outputs. There is a two second delay for each selected input and output. All of the outputs will be displayed if none of the outputs are selected for AUTOSCROLL. The “UP”, “DOWN” and “SELECT” buttons are scrolling mode section for the operation of the remaining buttons. The “LEFT” and “RIGHT” button toggles the program back to manual input and output scrolling mode. If none of the outputs have been selected on the manual input and output scroll mode, all of the outputs will scroll on the upper display when the “LEFT” and “RIGHT” button is pushed. The following illustration 27 shows the activation of the previous examples.
5. 1. The manual input and the manual output screen uses the “UP” and “DOWN” buttons in order to view the input and output selection “A001 1001”. this selection for viewing on the AUTOSCROLL screen. The letter “A” will appear in the lower right corner of the upper display. g00711949 Illustration 27 AUTOSCROLL Viewing Of “A001 1001” Selection
6. 2. Press the “UP” or “DOWN” button in order to show the input and output selection “P001 appears in the lower right corner of the upper display. g00711951 Illustration 28 AUTOSCROLL Viewing Of “P001 2011” Selection
7. 3. Press the “LEFT” and “RIGHT” button in order to go to the AUTOSCROLL screen. The input and output selections will scroll on the displays. The letter “A” will not be shown in the lower “RIGHT” corner. In this example, the associated input is active. The symbol “K1” will be visible when the input and output selections scroll. The upper LED display will be ON when the input and output selections scroll. The alarm for the LED display will be activated when the associated input is inactive and the output is active from the input state. 20 Systems Operation Section g00711952 Illustration 29 AUTOSCROLL Screen With “P001 2001” And “A001 1001” Input And Output Selections Activated. These Two Screens Will Continue To Be Repeated. i01351256 Diagnostic Code Viewing and Clearing SMCS Code: 1927 You can only view diagnostic codes and clear diagnostic codes by going through the I/O Monitoring/Programming Menu. The menu can only be accessed when an active diagnostic code “MODE” button from the initial screen of the I/O Monitoring/Programming Menu in order to reach button again will toggle the display to the Setpoint Viewing/Programming Menu. The upper display shows the “CID” (Component Identifier), “FMI” (Failure Mode Identifier), and the occurrence “COUNT”. The example that is shown in illustration 30 indicates that an internal relay has failed. • “CID 477” indicates that Relay 1 of the PRCM is the failed component. • The “FMI 4” indicates that the diagnostic code is a shorted relay coil. • “COUNT 1” indicates that the diagnostic code has happened one time. g00713050 Illustration 30 Displays of menu for viewing diagnostic codes Diagnostic Codes” for all definitions for diagnostic codes . When the “DIAG” symbol is FLASHING, the diagnostic code is active. The diagnostic code is present now. When the “DIAG” symbol is ON continuously, the diagnostic code is inactive. The diagnostic code is recorded in the fault log. The lower display shows the engine hours at the first occurrence of the diagnostic code and the last occurrence of the diagnostic code. The display will toggle between the two readings at an interval of two seconds . The illustration shows that the diagnostic code occurred at 10 engine hours. The following buttons are active in the mode for clearing diagnostic codes and viewing diagnostic codes: • The “UP” button scrolls up the list of diagnostic codes. • The“DOWN” button scrolls down the list of diagnostic codes. • The “SELECT” button will clear an inactive diagnostic code when the button is held for two seconds. If the diagnostic code is active, the “SELECT” button will reset the “COUNTS” back to zero. The hours for the engine can be reset to the current reading when the diagnostic code is inactive. • The “MODE” button Jumps to the setpoint viewing/programming menu. 21 Systems Operation Section i01344642 Relay Driver Module SMCS Code: 1927 g00710264 Illustration 31 Optio nal Relay Driver Module And Relay Board The Relay Driver Module (RDM) is an optional module. The RDM will increase the number of available outputs on the PRCM. Each RDM provides nine additional outputs. The outputs of the RDM are individually controlled by a serial data link from the PRCM. The outputs may drive the optional relay board. The outputs can be directly connected to horns, lamps, or other devices. The relay board contains nine relays. Each relay has a set of normally open contacts and each relay has a set of normally closed contacts. These relays are distinct from the seven relays that are contained within the PRCM Relay Module. These relays are in addition to the seven relays that are contained within the PRCM Relay Module. These relays are located on the rear of the PRCM. Once the output of the RDM is activated, the RDM will remain energized. The output will remain energized until the condition is cleared. The PRCM has two separate serial data links that enable the PRCM to be connected to two RDM’S. 22 Systems Operation Section g00710266 Illustration 32 23 Systems Operation Section Output Test The RDM will activate all outputs for ten seconds after the RDM receives an output signal. The RDM will activate for ten seconds unless the signal is deactivated. The test of the output signal is activated by connecting terminal 5 of the RDM to terminal 7 of the RDM. Data Link When the data link malfunctions, R1 output (terminal 2 of RDM) will be activated on and off at a rate of 0.5 Hz. Relays R2 through R9 will maintain the current status. Relays R2 through R9 could default to the OFF position. This is controlled by a jumper between terminal 6 and terminal 7 of the RDM. If the serial data link has a fault and a jumper is NOT present, the relay outputs (R2 through R9) will maintain the current status. If the jumper is present, R2 through R9 will default to the OFF position. • The maximum length of wire between the RDM and the PRCM is 305 m (1000 ft). • The operating voltage range is from 15 to 45 DCV. The RDM is designed to operate when the RDM is powered by 24 DCV or when the RDM is powered by 32 DCV. • The RDM is capable of operating with an earth ground or without an earth ground. • The RDM must share a common ground with the PRCM and the relay board. • The terminals that are on the RDM are push on blade connectors. The connectors are 6.4 mm (0.25 inch). • The screw terminals on the relay board are a 6-32 thread. • The driver outputs of the RDM are intended to drive incandescent lamps. Also, the driver outputs of the RDM are intended to power relay loads. The driver outputs sink up to 600 mA at 15 DCV to 45 DCV. The driver outputs of the RDM are protected against short circuits to “+B”. Also, the driver outputs of the RDM are protected against short circuits to “-B”. • The relay outputs of the relay board are protected by 1 amp fuses. The contacts are flashed with silver. The contacts are rated at 1 amp at 28 DCV. The relay coils draw 20 mA at 24 DCV. 24 Troubleshooting Section Troubleshooting Section Introduction i01351657 General Information SMCS Code: 1927 Personal injury or death can result from high volt- age. When power generation equipment must be in op- eration to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and cur- rent tests being made. When servicing or repairing electric power gener- ation equipment: • Make sure the unit is off-line (disconnected from utility and/or other generators power service) , and either locked out or tagged DO NOT OPERATE. • Remove all fuses. • Make sure the generator engine is stopped. • Make sure all batteries are disconnected. • Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, sta- tor and the generator is discharged. When the engine-generator, or any source to which the engine-generator is synchronized to, is operating, voltages up to 600V are present in the control panel. Do not short these terminal with line voltage to ground with any part of the body or any conduc- tive material. Loss of life or injury could result from electrical shock or injury from molten met- al. Do not connect generator to a utility electrical dis- tribution system unless it is isolated from the sys- tem. Electrical feedback into the distribution sys- tem can occur and could cause personal injury or death. Open and secure main distribution system switch, or if the connection is permanent, install a dou- ble throw transfer switch to prevent electrical feed- back. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circum- stances. i01351653 SMCS Code: 0785 troubleshooting the electrical system. Part Number Qty Description - 1 mm)(1). 4C-3406 1 Connector Repair Kit (Deutsch) 6V-7070 1 Digital Multimeter 9U-7330 1 Digital Multimeter PRCM. 25 Troubleshooting Section i01351676 Fault Identification SMCS Code: 1927-035 FAULT IDENTIFICATION LED Diagnostic Code DIAG Indicator Alarm/ Fault Type Internal Fault CID FMI Flashing Active Internal Diagnostic Code Alarm Fault CID FMI Flashing Active System Fault None CID FMI Continuous Inactive (Logged) Diagnostic Code Diagnostic Codes” of the PRCM for additional information. Fault Identification Procedure Diagnostic codes or alarms that are detected by the PRCM are shown in the display area of the PRCM. The PRCM uses the LED displays and diagnostic codes on the upper display in order to inform service personnel about a specific problem. Perform the following procedure in order to identify the diagnostic code that was detected by the PRCM. g00713266 Illustration 33 Display area of the Programmable Relay Control Module (1) Red LED display of the programmable alarm (2) Red LED display of the internal alarm fault (3) Yellow LED display of the alarm fault (4) Keypad (5) Lower LCD display (6) “CID”, “DIAG”, “FMI”, “PROG”, and “COUNT” (7) Upper LCD display
8. 1. Determine the LED display that is active on the left side of the PRCM (1), (2), or (3).
9. 2. View the diagnostic code on upper display (7) button in order to obtain the Diagnostic Code Viewing/Clearing screen.
10. 3. The status of the “DIAG” display area (6): • BLANK • FLASHING • CONTINUOUSLY ON
11. 4. Use the first column of table 4 and identify a
12. 3. condition from . Then, locate the alarm fault indicator that is activated.
13. 5. Use the second column of table 4 and find the diagnostic code that is shown on the upper display.
14. 6. Use the third column of table 4 which describes the status of the “DIAG” indicator.
15. 7. Read the last column in order to find the type “Troubleshooting Diagnostic Codes” of the PRCM for additional information. Connector Inspect” in order to troubleshoot connectors. This procedure is useful for problems that are intermittent. 26 Troubleshooting Section Diagnostic Code Procedures i01352362 Troubleshooting Diagnostic Codes SMCS Code: 1927-035; 7569 Diagnostic codes are associated with failed electrical components or circuits that provide information to the PRCM. Diagnostic codes are also associated with failed electrical components or circuits, that receive information from the PRCM. The diagnostic code closely identifies the cause of the failure. Each diagnostic code consists of the following items: a component identifier (CID), a failure mode identifier (FMI), and a fault indicator (“DIAG”). These items are shown on the upper display. A fault indicator can be active or inactive. The CID identifies the component that has failed in the system. The FMI describes the nature of the problem. When the “DIAG” indicator is FLASHING, the diagnostic code is active. This means that the diagnostic code is present. When the “DIAG” indicator is ON CONTINUOUSLY, the diagnostic code is inactive and the CID FMI is recorded in the fault log. See Systems Operation, “Diagnostic Code Viewing and Clearing” in order to view the fault log. When the “DIAG” indicator is not showing, there are NO diagnostic codes that are detected or recorded. Service personnel interpret the identifiers in order to assist with troubleshooting. The PRCM has a fault log to help with troubleshooting of diagnostic codes. Inactive diagnostic codes (CID FMI) are recorded in the fault log for viewing at a later time. Also, the number of occurrences are totalled and the number of occurrences are shown on the upper display with the CID and the FMI. During troubleshooting, it is sometimes necessary to disconnect the harness connector from the PRCM and a diagnostic code of CID 0590 FMI 09 is created. An FMI 09 describes the voltage that is above normal. This fact is also used as an aid in the troubleshooting process. Clear these created diagnostic codes after the particular problem is corrected and the diagnostic code is cleared. Operation, “Setpoint Viewing and Programming”. DIAGNOSTIC CODES for the PRCM For troubleshooting, see the procedure with the same CID and FMI. CID / FMI Description CID 0248 CAT data link: FMI 11 Short to + Battery or a short to −B of either CAT data link wire. CID 0268 PRCM Internal Memory: FMI 02 Signal out of range. CID 0333 Relay Driver Module (A): FMI 03 Voltage above normal. FMI 04 Voltage below normal. CID 0334 Relay Driver Module (B): FMI 03 Voltage above normal. FMI 04 Voltage below normal. CID 0477 PRCM Output Relay (1): FMI 03 Relay coil open circuit. FMI 04 Relay coil short circuit. CID 0478 PRCM Output Relay (2): FMI 03 Relay coil open circuit. FMI 04 Relay coil short circuit. CID 0479 PRCM Output Relay (3): FMI 03 Relay coil open circuit. FMI 04 Relay coil short circuit. CID 0480 PRCM Output Relay (4): FMI 03 Relay coil open circuit. FMI 04 Relay coil short circuit. CID 0481 PRCM Output Relay (5): FMI 03 Relay coil open circuit. FMI 04 Relay coil short circuit. CID 0482 PRCM Output Relay (6): FMI 03 Relay coil open circuit. FMI 04 Relay coil short circuit. CID 0483 PRCM Output Relay (7): FMI 03 Relay coil open circuit. FMI 04 Relay coil short circuit. CID 0590 ECM: FMI 09 ECM is not communicating to the PRCM. 27 Troubleshooting Section i01353172 PRCM CID 0248 - FMI 11 SMCS Code: 1927-035 Conditions Which Generate This Code: This diagnostic code is recorded when the engine ECM cannot send information or the ECM does not receive the expected information from the CAT data link. The PRCM uses the CAT data link in order to communicate with the engine ECM. The CAT data link consists of two wires. The wires connect the PRCM to the ECM. If the CAT data link fails, the relays will remain in the state required by the last valid input state, unless the relays are programmed Operation, “Setpoint Viewing And Programming”. with the engine ECM if the data link cable exceeds
16. 30. 5 m (100 ft). See Specifications, “Electrical” for

Source: manual:PRC Mod SENR6588-03.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.