0586039 JOHNSON SENDING UNIT ASSY.

Illustration 1 g00614752
Schematic For Unexpected Shutdown
Note: A slave relay is used only on Series 3500 engines with a 2301A governor and no fuel shutoff solenoid.
Illustration 2 g00614755
Fuel Control Relay For ETR Systems
Note: For Series 3408 and Series 3412 engines, the AFCR should be connected to SR terminal 87 instead of the fuel solenoid, and provided with F16.
Illustration 3 g00614757
Fuel Control Relay On ETS Systems
The CID 330 alerts the operator that the GSC did not control the engine shutdown. The GSC normally controls all engine shutdowns. If an outside influence causes the engine to shut down, the GSC indicates a CID 330. There is only one failure mode for a CID 330 and the mode is FMI 7 (faulty mechanical response).The diagnostic code causes the following sequence of events:
On a running engine, the GSC detects that the engine speed has dropped from the rated speed to 0 rpm when the GSC has not called for a shutdown.
The GSC determines that no fault for the engine speed sensor is present that explains the drop in the speed signal.
The GSC indicates a CID 330 FMI 7 and the GSC disables the engine from running. Note: An unexpected shutdown fault will initiate a signal from the shunt trip circuit breaker. Note: Diagnostic codes are created when the harness connector (40 contact) is disconnected from the GSC during these troubleshooting procedures. Clear these created diagnostic codes after the particular fault is corrected. In a properly operating system, when the harness connector is removed from the GSC, the following diagnostic codes are recorded.
CID 100 FMI 3 pressure sensor (engine oil)
CID 110 FMI 3 temperature sensor (engine coolant)
CID 111 FMI 3 fluid level sensor (engine coolant)
CID 190 FMI 3 speed sensor (engine)
CID 331 FMI 2 switch (engine control)
CID 336 FMI 2 switch (engine control)ProcedureThe following condition is a possible cause of a CID 330 FMI 7:
A component that is not under the control of the GSC has caused an engine shutdown.The GSC treats this diagnostic code 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. The fuse for the starting motor F4 on the relay module is removed in order to prevent the activation of the starting motor. Voltage measurements must be made quickly before the total cycle crank time (setpoint P17) elapses. The total cycle crank time has been defaulted to ninety seconds. See Systems Operation, "Engine/Generator Programming OP5". If a voltage measurement takes too long (more than 90 seconds), the GSC indicates an overcrank fault. The indicator for the overcrank shutdown will FLASH. In order to continue with a voltage measurement, the overcrank fault must be reset by turning the ECS to OFF/RESET. Then turn the ECS to START.
Perform an initial check. Before proceeding with the troubleshooting procedures, do the following steps:
Make sure that there are NO OTHER ACTIVE FAULTS. Erroneous troubleshooting and needless replacement of parts can be caused by a failure to check for other diagnostic codes. The operator will make many voltage measurements while the GSC is attempting to crank the engine. The GSC detects other diagnostic codes. If the GSC detects other diagnostic codes, the GSC will prevent the starting of the engine by sending a signal that turns off the fuel shutoff solenoid. Therefore, this signal will shut down the engine. The resulting voltage measurements would be exactly the opposite of what is expected in the procedures.
Check the fuel level and the fuel quality.
Check for a plugged fuel filter.
Check for a plugged air filter.
Refer to the Engine Service Manual if there is an obvious engine fault. Also, refer to the Engine Service Manual if there is an obvious fault with the fuel system.
If the generator set is equipped with an electronic governor, check the speed sensor.
Check the air shutoff solenoid for activation. If the air shutoff solenoid is activated and the air shutoff solenoid cannot be deactivated, begin troubleshooting with 20. Otherwise begin troubleshooting with 2.
Verify the diagnostic code.
Observe the upper display. Check that the CID 330 FMI 7 is showing. Expected Result: A CID 330 FMI 7 is showing as an active fault.Results:
No - A CID 330 FMI 7 is NOT showing. No active CID 330 FMI 7 exists. STOP.
Yes - Only a CID 330 FMI 7 is showing. Proceed to 3. (If an inactive CID 330 FMI 7 is showing in the fault log, check the history of the genset and proceed to 3.)
Check the system voltage.
Ensure that the engine is off. Measure the system voltage at the battery. Make a note of this measurement. The measurement for the system voltage is used for comparison in future steps of this procedure. Expected Result: For 24 volt systems, the system voltage should be from 24.8 to 29.5 DCV. For 32 volt systems, the system voltage should be from 33.1 to 39.3 DCV.Results:
OK - Proceed to 4.
NOT OK - System voltage is NOT correct. For troubleshooting, see the procedure for system voltage. STOP.
Check Governor And Rack.
Remove fuse F4 from the relay module.
Prepare to monitor the movement of the governor linkage and the fuel rack.
Turn the ECS to OFF/RESET and then to START.
Observe the governor and the fuel rack. Expected Result: The governor linkage and fuel rack should move in the direction to turn on the fuel. Results:
OK - The fault is in the engine or fuel system. Refer to the corresponding Engine Service Manual. STOP.
Not OK - Cannot see the governor linkage and fuel rack move in the direction to turn on the fuel. Proceed to 5.
Identify Fuel System. Determine the type of fuel solenoid used on the genset: ETR (energize to run) or ETS (energize to shutoff). Refer to the model number of the EMCP II on the inside bottom of the control panel and to the 129-4053 103-1582 print included within the panel to identify the type of fuel solenoid.
Check setpoint P01 for proper programming (0=ETR, 1=ETS). See Systems Operation, "Engine/Generator Setpoint Viewing OP2". Note: