Generator Set Control Panel for Switchgear Conversion Caterpillar

Note: This procedure requires the Remote Start Switch to be opened and/or closed many times. In order to ease the troubleshooting process, a switch that is locally acquired can be connected to terminal 57 and terminal 30 of the Remote Start Signal. The terminals are located in the Customer Connection Box.

1. Check The Obvious Causes.

   1. Check the fuel level and the quantity of the fuel. Refer to the Engine Service Manual.

   2. Check for a plugged fuel filter. Refer to the Engine Service Manual.

   3. Check for a plugged air filter. Refer to the Engine Service Manual.

   4. Check the air shutoff solenoid (if equipped) for activation. The solenoid must be deactivated in order to enable the engine to start. Also, the solenoid must be deactivated in order for the engine to run. The air damper must be reset.

   5. Check fuse F1 that is located in the control panel. Check fuse F14 that is located in the junction box. If either fuse is blown, proceed to Step 13.

   6. Check "CB2". "CB2" is the 20A circuit breaker that is located in the junction box. If the breaker is tripped, proceed to Step 14.

2. Check The Battery Voltage.

   1. With the engine OFF, measure the voltage of the system at the batteries.

      Expected Result: The voltage should be from 24.8 DCV to 29.5 DCV.

      Results:

      • OK: The voltage is correct. Proceed to the next Step.

      • Not OK: Further checking of the battery system is necessary. Proceed to Testing And Adjusting, "Charging System - Test".

3. Check The Engine Starting Function (Check 1).

   Voltage measurements are made during Step 3 through Step 8 while the operator is performing the simulated engine cranking. The starting motor is disabled. More than one attempt may be necessary in order to complete these steps.

   1. Disconnect the "B+" wire on the pinion solenoid of the starting motor. The "B+" wire remains disconnected for ALL of the remaining steps of this procedure.

   2. Prepare to measure the DC voltage from the disconnected "B+" wire of the pinion solenoid to the "B-" (battery negative terminal).

   3. Open the Remote Start Switch and close the Remote Start Switch.

   4. Measure the voltage from the disconnected "B+" wire of the pinion solenoid to "B-" (battery negative terminal).

      Expected Result: The voltage should be similar to the system voltage that was noted in Step 2. The voltage was ±2 DCV.

      Results:

      • OK: The voltage is correct. Therefore, the starting motor is faulty. Repair the starting motor or replace the starting motor. For more information, refer to the following manuals: Engine Service Manual and Starting Motor Service Manual.

      • Not OK: The voltage is not correct. Proceed to the next Step.

4. Check The Engine Starting Function (Check 2). The conditions of Step 3 remain. The "B+" wire is disconnected from the pinion solenoid.

   1. Prepare to measure the DC voltage from Wire 25 at the Starting Motor Magnetic Switch (SMMS) to "B-" (battery negative terminal). The starting motor magnetic switch is located in the junction box.

   2. Open the Remote Start Switch and then close the Remote Start Switch.

   3. Measure the voltage from Wire 25 at the SMMS to the battery negative terminal "B-".

      Expected Result: The voltage should be similar to the system voltage. The system voltage was measured in Step 2. The voltage was ±2.0 DCV.

      Results:

      • OK: The voltage is correct. Therefore, the engine wire harness between the junction box and the starting motor is faulty. Repair the engine wire harness or replace the engine wire harness. For more information, see Schematics And Wiring Diagrams, "Generator Set Wiring Diagram".

      • Not OK: The voltage is not correct. Proceed to the next Step.

5. Check The Engine Starting Function (Check 3). The conditions of Step 3 remain. The "B+" wire remains disconnected from the pinion solenoid.

   1. Prepare to measure the DC voltage from Wire 4 at the SMMS to the battery negative terminal. The battery negative terminal is located in the junction box.

   2. Open the Remote Start Switch and then close the Remote Start Switch.

   3. Measure the voltage from Wire 4 to the battery negative terminal.

      Expected Result: The voltage should be similar to the system voltage that was measured in Step 2. The voltage was ±2.0 DCV.

      Results:

      • OK: The voltage is correct. Therefore, the SMMS is faulty. Troubleshoot the SMMS and the related wiring. See Testing And Adjusting, "Starting Motor Magnetic Switch - Test".

      • Not OK: The voltage is not correct. Proceed to the next Step.

6. Check The Engine Starting Function (Check 4). The conditions of Step 3 remain. The "B+" wire is disconnected from the pinion solenoid.

   1. Check CB2. CB2 is the 20A circuit breaker that is located inside the junction box. Make sure that the circuit breaker is not tripped.

   2. If the circuit breaker is tripped, reset the circuit breaker and repeat Step 4.

   3. After repeating Step 4, proceed to Step 14 if the circuit breaker trips again. If the circuit breaker does not trip, proceed.

   4. Measure the DC voltage on each side of CB2.

      Expected Result: The voltage should be similar to the voltage that was measured in Step 2. The voltage was ±2.0 DCV.

      Results:

      • OK: The voltage is correct. Proceed to the next Step.

      • Not OK: The voltage is not correct. Therefore, the junction box wiring that is between CB2 and the SMMS is faulty. Repair the junction box wiring or replace the junction box wiring. See Schematics And Wiring Diagram, "Generator Set Wiring Diagram". STOP.

7. Check The Engine Starting Function (Check 5). The conditions of Step 3 remain. The "B+" wire should remain disconnected from the pinion solenoid.

   1. Prepare to measure the DC voltage from Wire 4 at the subpanel to the battery negative terminal.

   2. Open the Remote Start Switch and then close the Remote Start Switch.

   3. Measure the voltage from Wire 4 at the subpanel to the battery negative terminal.

      Expected Result: The voltage should be similar to the system voltage. The system voltage was noted in Step 2. The voltage was ±2.0 DCV.

      Results:

      • OK: The voltage is correct. Therefore, the wiring that is between the terminal for the subpanel and Connector 2 may be faulty. Also, the engine wiring harness that is between Connector 2 and the junction box is faulty. Repair the engine harness or replace the engine harness. See Schematics And Wiring Diagrams. STOP.

      • Not OK: Proceed to the next Step.

8. Check The Engine Starting Function (Check 6). The conditions of Step 3 remain. The "B+" wire is disconnected from the pinion solenoid.

   1. Prepare to measure the DC voltage from Wire 14 (Contact 13 of the control board) to "B-" (battery negative terminal).

   2. Open the Remote Start Switch and close the Remote Start Switch.

   3. Measure the voltage from Wire 14 (Contact 13 of the control board) to "B-".

      Expected Result: The voltage should be similar system voltage that was noted in Step 2. The voltage should be ±2.0 DCV.

      Results:

      • OK: The voltage is correct. Therefore, the Emergency Stop Push Button (ESPB) or the related wiring is faulty. Troubleshoot the ESPB and the related wiring. See Schematics And Wiring Diagram. STOP.

      • Not OK: Proceed to the next Step.

9. Check The Engine Starting Function (Check 7). The conditions of Step 3 remain. The "B+" wire is disconnected from the pinion solenoid.

   1. Prepare to measure the DC voltage from Contact 24 of the control board to "B-".

   2. Open the Remote Start Switch and then close the Remote Start Switch.

   3. Measure the voltage from Contact 24 of the control board to "B-".

      Expected Result: The voltage should be similar to the system voltage that is noted in Step 2. The voltage should be ±2.0 DCV.

      Results:

      • OK: The voltage is correct. Therefore, the control board is faulty. Replace the control board. STOP.

      • Not OK: Proceed to the next Step.

10. Check The Engine Starting Function (Check 8). The conditions of Step 3 remain. The "B+" wire is disconnected from the pinion solenoid.

    1. Prepare to measure the DC voltage from Wire 57 at the terminals of the customer connection box to "B-".

    2. Open the Remote Start Switch and then close the Remote Start Switch.

    3. Measure the voltage from wire 57 at the terminals of the customer connection box to "B-".

       Expected Result: The voltage should be similar to the system voltage. The system voltage is noted in Step 2. The voltage should be ±2.0 DCV.

       Results:

       • OK: The voltage is correct. Therefore, Wire 57 is open between the customer connection box and the control board. Repair the wiring or replace the wiring. STOP.

       • Not OK: The voltage is not correct. Fuse 1 (F1) may be faulty. Also, the Remote Start Switch may be faulty or the wiring that is located between F1 and the customer connection box is faulty. Proceed to the next Step.

11. Check The Engine Starting Function (Check 9). The conditions of Step 3 remain. The "B+" wire is disconnected from the pinion solenoid.

    1. Prepare to measure the DC voltage from Wire 7 to "B-". Wire 7 is located at the terminal of F1.

    2. Measure the voltage.

       Expected Result: The voltage should be similar to the system voltage that is noted in Step 2. The voltage from Step 2 is ±2.0 DCV.

       Results:

       • OK: The voltage is correct. Therefore, Wire 7 or the remote starting switch is faulty. Repair the wiring and/or the remote starting switch or replace the wiring and/or the remote starting switch. See Schematics And Wiring Diagram.

       • Not OK: The voltage is not correct. Proceed to the next Step.

12. Check The Engine Starting Function (Check 10). The conditions of Step 3 remain. The "B+" wire is disconnected from the pinion solenoid.

    1. Prepare to measure the DC voltage from Wire 1 to "B-".

    2. Measure the voltage.

       Expected Result: The voltage should be similar to the voltage that was measured in Step 2. The voltage is ±2.0 DCV.

       Results:

       • OK: The voltage is correct. Proceed to the next Step.

       • Not OK: The voltage is not correct. Therefore, the wiring that is located between fuse F1 and Connector 2 may be faulty. Also, the wiring that is between Connector 2 and the starting motor is faulty. Repair the wiring or replace the wiring. See Schematics And Wiring Diagrams. STOP.

13. Troubleshoot A Blown Fuse.

    1. Remove fuse F1 from the holder.

    2. Measure the resistance that is between the fuse terminal and "B-".

       Expected Result: The resistance should be greater than 5 ohms.

       Results:

       • OK: The resistance is greater than 5 ohms and the fuse is no longer blowing. Carefully check ALL wires that are connected to the appropriate terminal of F1 for abrasion or worn spots in the insulation that could be causing the short. Check wires in the panel and on the engine harness. See the various wiring diagrams in Schematics And Wiring Diagrams. Repair the wiring or replace the wiring as replacement is necessary.

       • Not OK: The resistance is less than 5 ohms. There is a short to "B-". See Schematics And Wiring Diagrams. Remove one component or wire at a time that is in series with F1 until the faulty component or wire is isolated. Repair the faulty component or replace the faulty component. Repair the faulty wiring or replace the faulty wiring. STOP.

14. Troubleshoot The Tripped Circuit Breaker. This Step continues troubleshooting from Step 1 or Step 5.

    1. While the circuit breaker is tripped, measure the resistance that is between Wire 24 and "B-".

       Expected Result: The resistance should measure 5 ohms or more.

       Results:

       • OK: Resistance is greater than 5 ohms and the circuit breaker is no longer tripping. Check ALL of the wires that are connected to the appropriate load terminals of CB2 for abrasion or worn spots. Check wires in the junction box and on the engine harness. See the various wiring diagrams in Schematics And Wiring Diagrams. Repair the wiring or replace the wiring as replacement is necessary.

       • Not OK: Resistance is less than 5 ohms. There is a short to "B-". See Schematics And Wiring Diagrams. Remove one component or remove wire at a time that is in series with CB2 until the faulty component or the wire is isolated. Repair the faulty component or replace the faulty component. Repair the wiring or replace the wiring. STOP.