Generator Set Control Panel for Switchgear Conversion Caterpillar

Expected Result: The indicator for the oil pressure should be ON and the engine should shut down.

Results:

• OK: The control panel is operating correctly for an oil pressure fault. Repeat Step 1 for the other possible shutdown faults. STOP.

• Not OK: If the indicator for the oil pressure is ON and the engine remains running, proceed to the next Step.

• Not OK: If the indicator for the oil pressure fault remains OFF, then the control board is not recognizing the "B-" signal. Verify that the control board is receiving the "B-" signal at the input for the oil pressure. The input for the oil pressure is found at contact 7. If the "B-" signal is being received, then the related wiring has an open circuit. STOP.

1. Open the Remote Starting Switch.

   Expected Result: The engine should shut down.

   Results:

   • OK: The engine shuts down. The system is functioning properly. Start the engine again. If the fault indicator is ON and the engine does not shut down, replace the control board. STOP.

   • Not OK: The engine does NOT shut down. Proceed to the next Step.

1. Push the emergency stop push button (ESPB).

   Expected Result: The engine should shut down.

   Results:

   • OK: The engine shuts down. Therefore, there may be an unwanted voltage from the battery positive terminal ("B+") that is keeping the fuel control relay (FCR) activated. Check the related wiring for this unwanted voltage. If necessary, repair the faulty wiring or replace the faulty wiring.

   • Not OK: The engine does NOT shut down. Proceed to the next Step.

1. Remove wire 27 from 1FCR in the junction box.

   Expected Result: The engine should shut down.

   Results:

   • OK: The engine shuts down. The contacts of the FCR are stuck or there is a wiring error. Troubleshoot the FCR and the related wiring. See Schematics And Wiring Diagrams, "Generator Set Wiring Diagram". STOP.

   • Not OK: If the engine does not shut down, proceed to the next Step.

1. Disconnect wire 27 from the fuel control solenoid.

   Expected Result: The engine should shut down.

   Results:

   • OK: The engine shuts down. Therefore, wire 27 is shorted to the battery positive terminal ("B+") in the engine harness. Troubleshoot the wiring and repair the wiring. See Schematics And Wiring Diagrams, "Generator Set Wiring Diagrams". STOP.

   • Not OK: The engine does NOT shut down. Therefore, the fuel shutoff solenoid is stuck or otherwise faulty. For information regarding troubleshooting the engine or repairing the engine, refer to the Engine Service Manual. STOP.