TP-5867 11/02 45Section 6 Component Testing and Adjustment
6.8 Fault Shutdown Test
Procedure
Verify the operation of the generator set overspeed,
overcrank, and low oil pressure shutdowns by
performing the following tests. If these tests are
inconclusive, test individual shutdown circuit
components (circuit board, wiring harness, switch, etc.)
as described earlier in this section.
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
6.8.1 Controller Fault Shutdown
Functions
Overspeed
Open the generator set output circuit breaker before
beginning the test. (See Figure 4-2 or Figure 4-3 for the
circuit breaker location.)
Start the generator set and manually adjust the engine
speed (by moving the throttle linkage) to exceed the
rated engine speed (3600 rpm @ 60 Hz and 3000 rpm
@ 50 Hz). Verify that the generator set shuts down when
the output frequency reaches 8 to 12 Hz above the rated
frequency. See Section 6.9.6 for more information
about the overspeed setting.
Low Oil Pressure (LOP) Shutdown
Connect a jumper wire from the LOP switch (lead 13) to
the generator set ground. See Section 4.2, Sequence
of Operation. Start the generator set. Verify that the
generator set shuts down after approximately 25--35
seconds of operation. Remove the jumper wire from the
LOP switch and ground. Start the generator set and run
it for at least 25--35 seconds to verify that the generator
set does not shut down.
Overcrank Shutdown
Disconnect the starter motor lead at the starter solenoid
(K20) terminal. Move the controller master switch to the
RUN position. Observe that the generator set simulates
cranking for 15 seconds and then rests for 15 seconds.
Check that the generator set shuts down after the third
crank/rest cycle. If the controller is set for continuous
cranking, verify that overcrank shutdown occurs after 45
seconds of continuous simulated cranking.
6.8.2 Fault Shutdown Switches
Check the low oil pressure and high engine temperature
shutdown switches by performing the following tests.
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
Low Oil Pressure (LOP) Switch
Refer to the engine service manual for the low oil
pressure (LOP) switch location. Remove the LOP
switch and install an oil pressure gauge to verify that the
engine oil pressure is within the range specified in
Section 1, Specifications, before testing or replacing the
LOP switch. To test the LOP switch, reinstall the switch
and start the generator set. If the unit shuts down,
disconnect lead 13 from the LOP switch and reset the
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