TP-6519 8/1766 Section 5 Component Testing and Adjustment
5.10 Fault Shutdown Tests
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 (wiring harness, switch, etc.) as described
elsewhere in this section.
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
DANGER
Short circuits. Hazardous voltage/current will 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.
5.10.1 Controller Fault Shutdown
Functions
Check the operation of the fault functions programmed
in the ADC-RES by performing the following tests. If the
ADC-RES does not operate as described, check the
controller configuration settings; see Section 4.5.1.
Also check the controller wiring and connections.
Overspeed Shutdown
The overspeed setting is factory-set and is not
adjustable. Verify that the following controller
configuration parameters are set correctly for your unit.
See the generator set installation manual for the
settings.
D System voltage/frequency parameter (UU)
D Unit configuration parameter (UC)
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely
hot during operation.
Open the generator set output circuit breaker before
beginning the test. (See Figure 4-1 for the circuit
breaker location.)
Connect a DVM to measure the output frequency. Start
the generator set and manually adjust the engine speed
by moving the throttle linkage.
Note: Be careful not to touch the hot silencer when
reaching in to adjust the throttle linkage.
Increase the engine speed (parameter 4P) to at least
115% of the r ated engine speed, 69 Hz on 60 Hz models
or 58 Hz on 50 Hz models. Verify that the generator set
shuts down on an overspeed fault (OS). If the
overspeed shutdown does not operate, the generator
set should shut down on an overfrequency fault (OF)
after approximately 5 seconds.
If the controller does not indicate an overspeed fault
(OS), check the wiring to the magnetic pickup (red and
black leads, P1-5 and P1-6). Check the magnetic
pickup resistance, air gap and voltage output; see
Section 5.9.4.
Low Oil Pressure (LOP) Shutdown
Connect a jumper wire from the LOP switch (lead 13) to
the generator set ground. 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.
High Engine Temperature Shutdown
Connect a jumper wire across coolant temperature
sensor (CTS) connections P1-18 and P1-19. Start the
generator set. Verify that the generator set shuts down
approximately 5 seconds after the generator set comes
up to speed. Remove the jumper wire. Start the
generator set and run it for at least 30 seconds to verify
that the generator set does not shut down.
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