11. 10. 2021. 09:24 SIS 2.

2006/01/31 Emergency Stop Switch Circuit - Test (RENR5096)

SMCS - 7332 i02485406

System Operation Description:

This procedure covers the following event codes:

E264-3 Emergency Stop Activated

This application is equipped with two emergency stop switches. One switch is located on the control panel. The other switch is located on the
generator enclosure. The Electronic Control Module (ECM) is configured to record an event when either of the switches is activated.

When an emergency stop switch is activated, the ECM input for the emergency stop switch at J1-23 will go high. This will cause the ECM to disable
injection to the cylinders. The engine shuts down. The ground circuit to the control solenoid of the start relay also becomes open. This removes
supply voltage (+Battery) to the engine ECM. The engine shuts down.

Illustration 1 g01215513
Schematic for the emergency stop switches

Test Step 1. Inspect the Electrical Connectors and the Wiring

A. Turn the battery isolator switch to the OFF position.

Illustration 2 g01186024
Location of the J1/P1 ECM connectors (typical left side engine view)

B. Thoroughly inspect the J1/P1 ECM connector. Inspect all of the connectors that are associated with the circuit. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for details.

Illustration 3 g01241230
Terminal locations at the P1 ECM connector for the emergency stop switch
(P1-23) Emergency stop
(P1-61) +Battery
(P1-63) +Battery
(P1-65) +Battery

C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors and the connector for the EMCP that are associated with the
circuit.

D. 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.

E. Check the harness and the wiring for abrasion and for pinch points from the batteries to the ECM.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch
points.

Results:

OK - The connectors and wiring appear to be OK. Proceed to Test Step 2.

Not OK - The connectors and/or wiring are not OK.

Repair: Repair the wiring and/or the connectors. Replace parts, if necessary.

STOP

Test Step 2. Check the Circuit for the Emergency Stop Switches

A. Turn the battery isolator switch to the OFF position.

B. Place both of the emergency stop switches in the RUN position.

C. Disconnect the wire in terminal location 85 from the start relay.

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11. 10. 2021. 09:24 SIS 2.0

D. Disconnect the J1/P1 ECM connectors.

E. Check continuity between terminal P1-23 at the ECM connector and the following test points. If an open circuit condition exists at a test point,
the problem is in the device, in the wire or in the connector that precedes the test point in the circuit. Refer to Illustration 1 as a reference.
Device  Terminal 
70 way general connector  Terminal 17 
Emergency stop switch (control panel)  Terminals on either side 
70 way general connector  Terminal 50 
Enclosure connector  Terminal 5 
Emergency stop switch (enclosure)  Terminals on either side 
Enclosure connector  Terminal 6 
P1 ECM connector  P1-61, P1-63, and P1-65 

Table 1

F. Restore the wiring to the original configuration.

Expected Result:

All measurements indicate that continuity exists at the test point.

Results:

OK - All measurements indicate that continuity exists. All measurements are correct. The harness is OK. Proceed to Test Step 3.

Not OK - At least one of the measurements indicates an open circuit condition.

Repair: There is an open circuit in the harness. There may be a problem with a connector. Repair the harness and/or the connectors.
Replace parts, if necessary.

STOP

Test Step 3. Check the Emergency Stop Switches

A. Ensure that both of the emergency stop switches are in the RUN position.

B. Check the operation of the emergency stop switch at the panel.

a. Disconnect terminals 17 and 50 (70 way general connector).

b. Check continuity across the terminals for the emergency stop switch (panel).
The correct measurement is continuity across the switch.

c. Place the emergency stop switch (panel) in the STOP position.

d. Check continuity across the terminals for the emergency stop switch (panel).
The correct measurement is no continuity across the switch.

C. Check the operation of the emergency stop switch at the enclosure.

a. Disconnect terminals 5 and 6 at the connector for the enclosure.

b. Check continuity across the terminals for the emergency stop switch (enclosure).
The correct measurement is continuity across the switch.

c. Place the emergency stop switch (enclosure) in the STOP position.

d. Check continuity across the terminals for the emergency stop switch (enclosure).
The correct measurement is no continuity across the switch.

D. Restore all wiring to the original configuration.

Expected Result:

The measurements agree with the results that are stated above.

Results:

OK - The measurements agree with the results.

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11. 10. 2021. 09:24 SIS 2.0

Repair: The circuit for the emergency stop is operating correctly at this time. There may be an intermittent problem in the harness or in a
connector. If an intermittent problem is suspected, refer to Troubleshooting, "Inspecting Electrical Connectors".

STOP

Not OK - The measurements did not agree with the results that are given above.
Repair: There is a problem with the emergency stop switch. Replace the switch.

STOP

AR21-UP, C5E1-UP, C5H1-UP, C5L1-UP, C9E1-UP, CYY1-UP, EKW1-UP, FST1-UP, FTE1-UP, L8B1-UP, LN91-UP, LT91-UP, LX91-UP, NBP1-UP,
NGP1-UP, NKL1-UP, NTX1-UP, RZ91-UP, S9L1-UP, S9P1-UP, X3R1-UP, X4R1-UP, X6X1-UP, XP71-UP, XPL1-UP

PPI-0001A599
2021/10/11
07:23:59+02:00
i02405608
© 2021 Caterpillar Inc.
Caterpillar:
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