Generator Set Control Panel for Switchgear Conversion Caterpillar

Engaged Starting Motor - Troubleshoot

Usage:

Check The Engine Starting Function (Check 1). Perform the following steps only when an engine start is simulated. The system for the fuel delivery is disabled.

Disable the fuel solenoid or disable the governor in order to prevent the engine from starting. This step will not prevent the engine from cranking.

Prepare to manually stop the engine from cranking. If necessary, the batteries may be disconnected.

Close the Remote Start Switch and allow the engine to crank.

Open the Remote Start Switch.
Expected Result: The engine should stop cranking.
Results:
- OK: Proceed to Step 5.
- Not OK: The engine continues to crank. Proceed to the next Step.

Check The Engine Starting Function (Check 2). The conditions of Step 1 remain. The fuel delivery is disabled and the engine is cranking.
1. While the engine is still cranking from the preceding Step, push the emergency stop push button (ESPB).
  Expected Result: The engine should stop cranking.
  Results:
  - OK: Check wire 14 from the ESPB to the control board for a short to "B+". If a short is not found, replace the control board. STOP.
  - Not OK: The engine continues to crank. Proceed to the next Step.

Check The Engine Starting Function (Check 3). The conditions of Step 2 remain. The fuel delivery is disabled and the engine is cranking.
1. Stop the engine. Disconnect the batteries from the generator set.
1. Remove wire 25 from the starting motor magnetic switch (SMMS1) in the junction box. For dual starting motors, also remove wire 26 from the other starting motor magnetic switch (SMMS2).
1. Reconnect the batteries to the genset.
1. Close the Remote Starting Switch and attempt to crank the engine.
  Expected Result: The engine should not crank.
  Results:
  - OK: The engine should not crank. Therefore, the Starting Motor Magnetic Switch (SMMS) or related wiring is faulty. Troubleshoot the SMMS and the related wiring. See Schematics And Wiring Diagrams. STOP.
  - Not OK: The engine continues to crank. Proceed to the next Step.

Check The Engine Starting Function (Check 4). The conditions of Step 3 remain. The fuel delivery is disabled and the engine is cranking.
1. Disconnect the batteries from the generator set in order to stop the engine.
1. Disconnect wire 25 from the pinion solenoid (PS1) of the starting motor. Also, remove wire 26 from the pinion solenoid (PS2) for dual starting motors.
1. Reconnect the batteries to the genset.
1. Close the remote start switch and attempt to crank the engine.
  Expected Result: The engine should not crank.
  Results:
  - OK: The engine does not crank. Therefore, wire 25 is shorted to the "B+". Wire 25 is located in the engine harness. Wire 26 is shorted to "B+" for dual starting motors.
  - Not OK: Troubleshoot the wiring. See the Schematics And Wiring Diagrams, "Generator Set Wiring Diagram". STOP.

Check The Starter Motor Cycling. This step continues troubleshooting from Step 1. The conditions of Step 1 remain. The fuel delivery is disabled.
1. Close the Remote Starting Switch.
  Expected Result: The starting motor should cycle ON and OFF according to preset cycle times. The factory default is a 10 second crank time, 10 second rest time and 53 second duration time. The duration time is set to 53 seconds. This duration time will allow three complete 10 second cranks. Between cranks, there is a 10 second rest.
  Results:
  - OK: If the starting motor cycles correctly, the problem is not present. STOP.
  - Not OK: The starting motor remains ON and the starting motor does not stop. The starting motor is faulty. Troubleshoot the starting motor. Refer to the Starting Motor Service Manual and/or the Engine Service Manual. STOP.