The engine does not shut down when a shutdown fault occurs.
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| Illustration 1 | g00681895 |
System Schematic For Electronic Control Relay | |
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| Illustration 2 | g00681904 |
System Schematic For Air Shutoff Relay (ASR) | |
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| Illustration 3 | g00681915 |
System Schematic For Engine Control Switch (ECS) | |
Note: It is critical that GSC setpoint 023 is correct for the engine application. Ensure that setpoint 023 is programmed correctly for the engine application before continuing with this procedure.
There are several possible causes when a shutdown fault occurs and an engine does not shut down:
- Operator Error: The operating conditions of the generator may not be understood by the operator. Ensure that the condition is one that should cause an engine shutdown.
- Programming Error - Fault Is Overridden Or Disabled: It is possible to program the GSC in order to override certain shutdown faults. An overridden shutdown fault will be treated as an alarm fault. The YELLOW fault alarm indicator will be FLASHING instead of the RED fault shutdown indicator. If the GSC is programmed in order to disable a particular fault, there will not be any fault indicators or codes shown on the GSC. In these cases, it is a good idea to check any setpoints related to that fault. For example, if a genset is not shutting down when an overvoltage fault occurs, make sure setpoint P104 (Overvoltage shutdown enable) is programmed correctly. It is also possible to program the engine ECM to override or ignore certain shutdown faults. See Troubleshooting, SENR1003, "3500B EPG Engines" or Troubleshooting, RENR2227, "3406E EPG Engines" for more information on programming the engine ECM.
- Programming Error - Setpoints Incorrect For Application Or Customer Needs: It is possible to program the GSC setpoints to a value that does not allow the situation to be recognized by the GSC as a shutdown condition. In this case, check the appropriate setpoints for correct values. For example, if the genset is not shutting down when a high coolant temperature condition occurs, make sure setpoint 015 (High Water Temperature Shutdown) is correct for the application.
- Faulty Component: Some examples of faulty components that could prevent the GSC from shutting down the engine are: engine ECM, GSC and a broken or shorted harness wire.. In this case, the GSC or engine ECM will be issuing a command to shut down the engine due to a diagnostic code, but the engine remains running.
Test Step 1. CHECK FOR DIAGNOSTIC CODES
- Check the GSC for a diagnostic code on the upper display.
Expected Result:
The GSC should show a diagnostic code on the upper display.
Results:
- YES - The GSC shows a diagnostic code on the upper display.
Repair: See theTesting and Adjusting section of this book for the diagnostic code that is displayed on the GSC.
Stop.
- NO - The GSC does NOT show a diagnostic code on the upper display. Proceed to Test Step 2.
Test Step 2. CHECK THE YELLOW FAULT ALARM INDICATOR
- Check the display of the GSC for the yellow fault alarm indicator.
Expected Result:
The yellow fault alarm indicator is ON CONTINUOUSLY.
Results:
- YES - The yellow fault alarm indicator is ON CONTINUOUSLY. The GSC has been programmed to override the normal shutdown response. The setpoints have been modified and the GSC treats the condition as an alarm fault. The engine will continue to run.
Repair: In order to view the setpoints, seeSystems Operation, "Engine/Generator Setpoint Viewing OP2". In order to reprogram the setpoints, see Systems Operation, "Engine/Generator Programming OP5-0".
Stop.
- NO - The yellow fault alarm indicator is not illuminated at all. Proceed to Test Step 3.
Test Step 3. CHECK FOR THE RED FAULT SHUTDOWN INDICATOR
- Check the display area of the GSC for the red fault shutdown indicator.
Expected Result:
The red fault shutdown should be FLASHING.
Results:
- YES - The red fault shutdown indicator is FLASHING and the engine remains running. Proceed to Test Step 4.
- NO - All fault indicators are.OFF. A problem that is occurring should cause the GSC plus to shut down the engine. It is possible to program the GSC setpoints to a value that does not allow the situation to be recognized by the GSC as a shutdown condition.
Repair: Check the appropriate setpoints for correct values. In order to view the setpoints, see System Operation, "Engine/Generator Setpoint Viewing OP2". In order to reprogram the setpoints, see System Operation, "Engine/Generator Programming OP5-0".
Stop.
Test Step 4. CHECK K1 INDICATOR ON GSC DISPLAY
- The red fault shutdown indicator is FLASHING and the engine remains running.
- Check the upper display of the GSC.
Expected Result:
The K1 symbol is showing on the GSC upper display.
Results:
- YES - The K1 symbol is showing on the GSC upper display. The red fault shutdown indicator is FLASHING and the engine remains running. The GSC may have failed.
Repair: The GSC may have failed. It is unlikely that the GSC has failed. Exit this procedure and perform this entire procedure again. If the problem remains, replace the GSC. See Testing and Adjusting, "EMCP Electronic Control (Generator Set)-Replace"
Stop.
- NO - The K1 symbol is not showing at call on the GSC upper display. Proceed to Test Step 5.
Test Step 5. CHECK THE GSC RELAY MODULE.
The engine remains running and the red fault shutdown indicator is FLASHING.
- In the generator housing, remove BOTH of the wires from RM-13 on the GSC.
Expected Result:
The engine should shut down.
Results:
- OK - The engine shuts down.
Repair: The GSC Relay Module may have failed. It is unlikely that the GSC Relay Module has failed. Exit this procedure and perform this entire procedure again. If the problem remains, replace the GSC Relay Module. See Testing And Adjusting, "EMCP Electronic Control (Relay Module) - Replace".
Stop.
- NOT OK - The engine runs and the engine will start. Proceed to Test Step 6.
Test Step 6. CHECK THE SYSTEM BY USING THE ESPB.
The engine remains running and the red fault shutdown indicator is FLASHING.
- Push the emergency stop push button (ESPB).
Expected Result:
The engine should shut down.
Results:
- OK - The engine does shutdown. Proceed to Test Step 7
- NOT OK - The engine does NOT shut down.
Repair: The engine ECM made have failed. Refer to Troubleshooting, SENR1003, "3500B EPG Engines" or Troubleshooting, RENR2227, "3406E EPG Engines".
Stop.
Test Step 7. CHECK THE WIRING BETWEEN THE ENGINE ECM AND THE GSC.
The engine remains running and the red fault shutdown indicator is FLASHING.
- Check the wiring between RM-13 of the GSC and J1-8 and J1-14 of the engine ECM. Check for shorts, open connections, or damaged wires.
Expected Result:
The wiring has a short, open connection, or is damaged.
Results:
- OK - The wiring is damaged.
Repair: Troubleshoot and repair the wiring. See Generator Set Wiring Diagram in Testing And Adjusting, "Schematics And Wiring Diagrams". Verify that the repair corrects the problem.
Stop.
- NOT OK - The wiring is not damaged at all. The engine ECM may have failed.
Repair: The engine ECM made have failed. Refer to Troubleshooting, SENR1003, "3500B EPG Engines" or Troubleshooting, RENR2227, "3406E EPG Engines".
Stop.