3054 and 3056 Engines 520 Generator Set Control Panel Caterpillar

Troubleshooting

Usage:

3054 CHN

Note: Use the diagnostic feature on the P808 interface in order to troubleshoot. Refer to the "P808 For Windows" software manual for instructions. The interface will display the state of the module, any alarm conditions that are present, and the state of all the inputs and the outputs. The diagnostic interface should be used to troubleshoot when it is possible.

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Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
When servicing or repairing electric power generation equipment:

Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE.

Remove all fuses.

Make sure the generator engine is stopped.

Make sure all batteries are disconnected.

Make sure all capacitors are discharged.

Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

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When the engine-generator, or any source to which the engine-generator is synchronized to, is operating, voltages up to 600V are present in the control panel.

Do not short these terminal with line voltage to ground with any part of the body or any conductive material. Loss of life or injury could result from electrical shock or injury from molten metal.

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Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or death.

Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electrical feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circumstances.

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Illustration 1	g00837735
520 Control Module (Generator Set) (1) Indicator for oil pressure (2) Indicator for alarm (3) Indicator for coolant temperature (4) Automatic start position (5) Indicator for engine overcrank

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Table 1
Symptom	Possible Remedy
Unit does not operate	Select AUTO (4) on the control module. Check the battery and check the wiring to the unit. Check the DC power supply. Check the fuse for the DC power supply.
Unit shuts down	The DC power supply voltage should be between 8 VDC and 35 VDC. Check that the operating temperature is below 55 °C (131 °F). Check the fuse to the DC power supply.
Unit locks out on Emergency Stop	If an emergency stop switch is not configured, connect the emergency stop input to the positive terminal of the DC power supply. Check that the emergency stop switch is functioning correctly. Check for an open circuit.
Intermittent sensor fault	Ensure the ground shield for the engine speed sensor is connected at one end only. If the ground shield is connected at both ends, the ground shield will act as an antenna and the ground shield will conduct random voltages.
Indicator for oil pressure (1) operates after engine has started	Check the engine oil pressure. Check the oil pressure switch and check the wiring. Check that the configured polarity is correct.
Indicator for coolant temperature (3) operates after engine has started	Check the engine temperature. Check the switch and check the wiring. Check the configuration of the input. The input is normally open or normally closed.
Shutdown fault operates	Check the appropriate switch and check the wiring of the illuminated fault indicator. Check the configuration of the input. If the indicator for alarm (2) is the only indicator that is illuminated, refer to the second note in Systems Operation, "Alarm Operation".
Warning fault operates	Check the appropriate switch and check the wiring of the illuminated fault indicator. Check the configuration of the input. If the indicator for alarm (2) is the only indicator that is illuminated, refer to the second note in Systems Operation, "Alarm Operation".
Indicator for engine overcrank (5) activated after 3 attempts to start	Check the wiring of the fuel solenoid. Check the fuel level. Check the battery. Check that the battery signal is present on the fuel solenoid output of the module. Check that the speed sensing signal is present on the control panel inputs. Refer to Operation and Maintenance Manual, SEBU7577, "3054 and 3056 Marine Generator Set".
Continuous starting of generator when in AUTO (4)	Check that no signal is present on the remote initiating contact. Check that the configured polarity is correct.
Engine fails to start on receipt of remote start signal	Check that the start delay timer has expired. Check that a signal is on the remote initiating contact.
Preheat does not operate	Check the wiring to the connectors for the engine block heater. Check the battery. Check that the battery signal is present on the preheat output of module. Check that preheat is selected in the configuration menu.
Starting motor does not operate	Check the wiring to the starter solenoid. Check the battery. Check that the battery signal is present on the starter output of the module. Ensure that the emergency stop input is connected to the positive terminal of the DC power supply.
Engine runs but generator will not take load	Check that the warm up timer has expired. Check the configuration in order to ensure that the output has been selected to give load transfer.