Troubleshooting Section Introduction sseeroa General Information SMCS Code: 4490 FeO te Personal injury or death can result from high volt- age. ‘When power generation equipment must be in op- ration to make tests and/or adjustments, high voltage and current are present, improper test equipment can fall and present a high voltage shock hazard to its user. Wake sure the testing equipment is designed for and correctly operated for high voltage and cur- rant tests belng made. When servicing or repairing electric power gener- ation equipment: |* Make sure the unit is off-line (disconnected ‘rom utllity 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. Moke sure all capacitors are discharged. lure to do so could result in personal Injury or \. Make sure residual voltage in the rotor, sta- ‘and the generator Is discharged. , OF any source to the engine-generator is synchronized to, is , voltages up to GOOV are present in the Panel. ‘not short these terminal with line voltage to with any part of the body or any conduc- material. Loss of life or injury could result electrical shock or Injury from molten met- PON Do not connect generator to a utility electrical dis- tribution system unless itis isolated from the sys- tem. Electrical feedback Into the distribution sys- tem can occur and could cause personal injury or death, ‘Open and secure main distribution system switch, ‘or if the connection is permanent, install a dou- ble throw transfer switch to prevent electrical feed- back. 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 ciroum- ietse6r08 Service Tools ‘SMCS Code: 0785, Table 18 ‘Tools Needed Part ‘Deseription| “Amount Number 46-3406 | Connector Kit 1 4 mm Hex Wrench for 1 fastener on GSC+ connector ‘6V-7070 _| Digital Mutimeter 1 98-7930 | Multimeter {Optional for 4 frequency and duty cycle measurements 148-4080 _| Digital Multimeter (RS-232) 1 7%-1710 | Cable Probes 1118 Troubleshooting Section ‘raser8 Fault Identification SMCS Code: 4490-035 Tibie 1 Fault identification Indleator Fault Cade on upper | DIAG Indicator lett side of ase ‘slsplay Fault Type See Tople Fault Alarm CID FM Flashing Active Alarm Troubleshooting: Diagnostic Codes SP1, SP2, SPS, SPat? ‘Absent ‘ative Alar Diagnostic System Procedures, “SP Fault Code” "ALA th ALAS ‘Absent ‘tive Alarm Diagnostic Syatern Procedures,“ Fault Cos Fault Shutdown ID Fu Flashing “have Shutdown | Troubleshooting . Diagnostic Codes ‘SP1, SP2, SP3, SP4 Absent Active Shutdown Diagnostic System Procedures, “SP Fault Code” TALS thru ALIS ‘Absent ‘ative Alarm Diagnostic System Procadures, “AL Fault Cove" Dedicated Shutdown Flashing ‘Absent ‘Absent fetve Alarm | Troubleshooting . Dedicated Shutdown (on Continuously ‘Absent ‘Absent fete Shutdown | persancee iD FMi@ ‘On Continuously Inactive Alerm Troubleshooting Diagnostic Codes iD FM ‘On Continuausly | inacive Shutdown | Troubleshooting Diagnostic Codes SPt, SP2, SP, SP4 ‘Absent inactive Shutdown | Diagnostic System None Procedures, “SP Fault Code” "ALS through ALIS ‘absent inactive Alarm | O'agnostc Systern Procedures, AL. Fault Code" ‘Absent ‘Absent Undiagnosed | Symptom Procedures Shutdown {Fu codes shown afr elarm codes key i pressed © faut ode s stored inthe aut og of te GSC. To view te fat coce, 869 Stems Oparaion, Fault Log Viewing OP win tho top Serves ModeEREVAN a oc ee \ 37 !6 (QOOD s00 OP ‘mutation 91 614728 ae Oe (2) Spare fault indicators {3} Fault shutdown indicator a {oto display (@) DIAG incicator Fautts that ate detected and diagnosed by the GSC+ ate shown to service personne! in the display area of the GSC+. The GSC+ uses dedicated shutdown indicators (1), fault shutdown indicator @, fault alarm indicator (4), "DIAG" indicator (@), upper display (5) and lower display (6) to tel service personne! about a fault. Perform the following procedure in orcer to identity the fault tha: is detected by the GSC+, Note: The "DIAG" indicator (8) functions when diagnostic information is available from the GSC+. 1. Make a note of the indicators that are functioning on the ieft side of the "GSC+" 2. View the fauit code on the upper display (5). I the fault alarm indicator (4) is FLASHING and no fault code is present on the upper display (6), press the alarm codes key in order to view the fault code. &. Make a note of whether or not "DIAG" indicator (@) is FLASHING ON CONTINUOUSLY or ABSENT. 4.0n the fault identification chart, look at the first column, Locate the fault indicator that is functioning. 119 “Troubleshooting Section 8. Go to the second column in the chart. Find the fault code that is presently shown on the upper display (8). 6. Go to the third column in the chart which Gescribes the status of “DIAG" indicator (8). 7. Read the last two columns in order to find the type of fault and comesponding topic within this ‘module.120 Troubleshooting Section Symptom Procedures so2esecr Starting Motor Remains Engaged (for EUI and PEEC Engines) SMCS Code: 1463-035 ‘SN: 4BZ1-Up; 1EZ1-Up ‘SN: SKW1-Up; 1FZ1-Up, ‘SIN: 6GW1-Up: 1621-Up S/N: BNW1-Up; 1HZ1-Up. ‘SIN: BAZ1-Up, 1MZ1-Up_ ‘System Operation Description: ‘The starting motor remains engaged after the ‘engine has started. ‘OrNERATOR Sey OnE ROL eeces ese Onn aS esPa ON ENCE QSURE, suagiaee syguee IWustration 92 ‘Schematic For Stating Motor Relay (SMR) On *PEEC" Enginescenegyon oe a aes askation 93 080889 Schematic For Starting Motor Pela (SMR) On“EUM Engines ‘Test Step 1. CHECK THE SETPOINTS. This test step checks the following setpoints: PO11 (crenk terminate speed), P01? (total cycle crank time), and PO18 (cycle crank time). ‘A View the setpoints and make a note of setpoints PO11, PO17 and PO18., See Systems Operation, “Engine/Generator Setpoint Viewing OF2-0". B. Compare the setpoints with the specified setpoints of the particular generator set. The default value for PO11 is 400 rpm. The default value for PO17 is 90 seconds. The default value for PO18 is 10 seconds, Note: Engines that are equipped with prelube pumps may require cycle crank times (setpoint P08) of 380 seconds or more Expected Result: The setpoint vaiue that is being viewed should match the specified setpoint value. 121 “Troubleshooting Section ‘© OK ~ The setpoint is correct. Proceed to test step 2. '* NOT OK ~ The setpoint that is being viewed does not agree with the specified setpoint. Repair: Reprogram setpoints PO11, PO17 and PO18. See Systems Operation, “Engine/Generator Programming OPS.0°. STOP, Test Step 2, CHECK THE START FUNCTION OF THE ENGINE. The foitowing procedure will require checks to be made during simulated engine starting. Disable the fuel system. AA. Disable the fuel shutoff solenoid or the PEEC in ‘order to prevent the engine from starting but not {from cranking. To disable the EU! engine ECM rernove the J1-40 pin connector. B. Prepare to manually stop the engine from cranking, # necessary. Turn the battery disconnect switch to the OFF position or shut the engine off by using mechanicai means. ©. Turn the engine control switch (ECS) to the START posttion. Allow the engine to crank, D. Turn the ECS to the OFF/RESET position, Expected Result: The engine should stop ranking, Resutts: '* OK ~The engine does not crank. Proceed to test step 6. ‘* NOT OK — The engine continues to crank Proceed to test step 3, Test Step 3. CHECK THE START FUNCTION OF THE ENGINE. A. The conditions of the previous step remain. The fuel system is disabled. The engine is cranking, B. While the engine is still cranking, push the emergency stop push button. Expected Result: The engine should stop cranking,122 Troubleshooting Section Results: ‘© YES — The engine does not crank, Repair: Check the wire on "RM-18" of the relay ‘module for a short to +battery. Repair the short ‘or replace the harness. if a short is not found, replace the relay module, See Testing And Adjusting, "Relay Module - Replace”. STOP. ¢ NO -The engine continues to crank. Proceed otest stop 4. Test Step 4, CHECK THE START FUNCTION OF THE ENGINE. ‘A. The conditions of the previous step remain, The fuel system is disabled. The engine is cranking. Stop the engine, Turn the battery disconnect ‘witch to the OFF or shut the engine off by using mechanical means, €. Remove all wires from TS1-25 in the generator housing. For dual starting motors, remove all wites trom TS1-26. 1D. Turn the ECS to START. Attempt to crank the engine. Expected Result: The engine should not crank. Results: © OK ~ The engine does not crank, Repair: The "SMS" or related wiring has failed. Troubleshoot the “SMMS" and the related wiring See the Generator Set Wiring Diagram in Testing And Adjusting, “Schematics & Wiring Diagrams", stop. # NOT OK — The engine continues to crank Proceed to test step 5. Test Step 5. CHECK THE START FUNCTION OF THE ENGINE. ‘A, The conditions of the previous step remain. The fuel system is disabled. The engine is cranking. Stop the engine. Tum the battery disconnect switch to OFF of shut the engine off by using mechanical means. . Disconnect the “B+” wire on the pinion solenoid of the starting motor. 1D, Tum the ECS to START and attemet to crank the engine, Expected Result: The engine should not crank. Results: * OK ~ The engine does not crank. Repair: On "PEEC” engines, wite 052-125 of 125-152 in the engine harness is shorted to the battery. On "EUS" engines, wire 304-WH or 314-PU in the engine harass is shorted to the battery. Troubleshoot the wiring. See the Generator Set Wiring Diagram in Testing And Adjusting, "Schematics And Wiring Diagrams” STOP, * NOT OK - The engine continues to crank Repair: The starting motor has failed. Troubleshoot the starting motor Refer to the Starting Motor and/or Engine Service Manuals. STOP Test Step 6. CHECK THE STARTING MOTOR CYCLING. ‘A. The fuel delivery is disabled. B. Turn the ECS to the START position, Expected Result: ‘The starting motor shou'd cycle on and off according 10 setpoint PO18 (cycle crank time). Results: © OK ~ If the starting motor cycles correctly, the problem is not present. STOP. * NOT OK ~ If the starting motor remains engaged, the starting motor has faved. Repair: Troubleshoot the starting motor. Refer to the Starting Motor andjor Engine Service Manuals. STOP,oman Starting Motor Remains Engaged (for MUI 3412C, 3508, 3512, 3516 Engines) ‘SMCS Code: 1453-035 SIN: BNS1-Up_ ‘SIN: SES1-Up ‘SIN: SPW1-Up; 1JZ1-Up SIN: BWW1-Up; 1KZ1-Up. ‘SIN: BTW1-Up; 1121-Up ‘SMM: 4BZ1-Up; 3FZ1-Up- |’ System Operation Description: The starting motor remains engaged after the |, engine has started. oReseyt whet Isai? poarzeani For Starting Motor Relay (SMA) 128, ‘Troubleshooting Section Test Step 1. CHECK THE SETPOINTS. ‘This test step checks the following setpoints: PO11 (crank terminate speed), PO17 (total cycle crank time), and P018 (cycle crank time). A. View the setpoints and make a note of setpoints PO11, PO17 and POIB. See Systerns Operation, “Engine/Generator Setpoint Viewing OP2-0" B. Compare the setpoints with the specitied selpoints of the particular generator set. The default value for P01 is 400 rpm. The default value for PO17 is 90 seconds. The default value for PO18 is 10 seconds. Expected Result: ‘The setpoint value that is being viewed should maich the specified setpoint value. Resutts: * OK ~The setpoint is correct. Proceed to test step 2. @ NOT OK ~The setpoint that is being viewed dooe not agree with the specified setpoint, Repair: Reprogram setpoints PO11, PO17 and O18. See Systems Operation, “Engine/enerator Programming OPS-0" STOP. Test Step 2, CHECK THE START FUNCTION OF THE ENGINE. The following procedure will require checks to be ‘made curing simulated engine starting. Disable the fuel system. ‘A. Disable the fuel shutoff solenoid or the governor in order to prevent the engine from starting but not from cranking B. Prepare to manualiy stop the engine from ‘cranking, if necessary. Turn the battery disconnect switch to the OFF position or shut the engine off by using mechanical means. Turn the engine control switch (ECS) to the START position. Allow the engine to crank, D. Turn the ECS to the OFFIRESET position Expected Result: The engine should stop cranking124 ‘Troubleshooting Section Results: # OK ~ The engine does not crank. Proceed to test step 6. © NOT OK ~The engine continues to crank Proceed to test step 3. Test Step 3. CHECK THE START FUNCTION OF THE ENGINE. A. The conditions of the previous step remain. The fuel system is disabled. The engine is cranking B. While the engine 's stil cranking, push the ‘emergenoy stop push button. Expected Result: The engine should stop cranking. Results: © YES ~ The engine does not crank. Repair: Check the wire on “RM-18" of the relay module for a short to +baltery. Repair the short of replace the harness. If a short is not found, replace the relay module. See Testing And Adjusting, "Relay Module - Replace". STOP, ‘* NO ~The engine continues to crank. Proceed to test step 4. Test Step 4. CHECK THE START FUNCTION OF THE ENGINE. ‘A. The conditions of the previous step remain, The fuel system is disabled. The engine is cranking, B, Stop the engine. Turn the battery disconnect ‘switch to the OFF or shut the engine off by using mechanical means. C. Remove all wires from the output terminal of slarling motor magnetic switch (SMMS) in the junction box D. Tum the ECS to START. Attempt to crank the engine. Expected Result: The engine should not crank. Results: * OK — The engine does not crank, Repair: The “SMS" or related wiring has failed Troubleshoot the "SMMS" and the related wiring. See the Generator Set Wiring Diagram in Testing And Adjusting, “Schematics & Wiring Diagrams STOP, ‘NOT OK ~ The engine continues to crank. Procead to test step 5. Test Step 5. CHECK THE START FUNCTION OF THE ENGINE. A. The conditions of the previous step remain. The {ual system is disabled, The engine is cranking. B. Stop the engine. Turn the battery disconnect swfch to OFF or shut the engine off by using mechanical means. ©. Disconnect the "B+" wire on the pinion solenoid of the starting motor. D. Tum the ECS to START and attempt to crank the engine. Expected Result: The engine should not crank. Results: * OK — The engine does not crank. Repair: The wire to the pinion solenoid in the engine harness is shorted to the battery. ‘Troubleshoot the wiring. See the Generator Set Wiring Diagram in Testing And Adjusting, "Schematics And Wiring Diagrams" stop. * NOT OK — The engine continues to crank Repair: The starting motor has failed. Troubleshoot the starting motor. Refer to the Starting Motor andior Engine Service Manuals. STOP. Test Step 6. CHECK THE STARTING MOTOR CYCLING. ‘A. The fuel delivery is disabled. B. Turn the ECS to the START position. Expected Result: The starting motor should cycle on and off according to setpoint PO18 (cycle crank time),Results: « OK ~ If the starting motor cycles correctly, the problem is not present, STOP. © NOT OK ~ If the starting motor remains engaged, the starting motor has failed. Repair: Troubleshoot the starting motor. Refer to the Starting Motor andlor Engine Service Manuals. TOP. ‘ssra0s Engine Does Not Shutdown (for EUI Engines) SMCS Code: 4490-035 ‘SIN: SKW1-Up; 1FZ1-Up. ‘SN: 6GW1-Up; 1GZ1-Up SIN: BNW1-Up; 1HZ1-Up ‘SN: 8AZ1-Up; 1MZ1-Up ‘System Operation Description: The engine does not shut down when a shutdown fault occurs. ceagaion va = comet (eoey fo Sean at LBL sass “aloe Bann ustration 95 900681895 ‘System Schomatic For Electronic Control Relay 126 ‘Troubleshooting Section ease © aA CYLINDER ONLY ons T008 IMustration 96 ‘System Schematic For Air Shutol Relay (ASA)126 ‘Troubleshooting Section SENERATOR ar conreot SAS BaaLaBe eso ‘tuswation 67 porns System Schomatic For Engine Contrat Switeh (ECS) Note: Its critical that GSC+ setpoint PO23 is correct tor the engine application. Ensure that setpoint PO23 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: itis 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 faut shutdown indicator. If tne GSC+ 's programmed. in order to disable a particular fault, there will not be any fault indicators or codes shown on the GSC+. In these cases, itis a good idea to check any setpoints related to that fauit. For example, if a genset is not shutting down when an overvoltage fault occurs, make sure setpoint P104 (Overvoltage shutdown enable) is programmed Correctly. Itis also possible to program the engine ECM to override or ignore certain shutdown faults. See Troubleshooting, SENR1003, “35008 EPG Engines" or Troubleshooting, RENR2227, "3406 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 conaition. In this case, chack the appropriate setpoints for correct values. For example, if the genset is not shutling down when a high coolant temperature condition occurs, make sure setpoint PO15 (High Water Temperature Shutdown) is correct fer 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 shorled harness wite.. In this case, the GSC+ or engine ECM will be issuing @ command to shut down the engine due to a diagnostic code, but the engine remains running. ‘Test Step 1. CHECK FOR DIAGNOSTIC CODES ‘A. Check the GSC+ for a diagnostic code on the supper display. Expected Result: The GSC+ should show a diagnostic code on the upper display. © YES - The GSC+ shows a diagnostic code on the upper display.127 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 shaw a diagnostic code on the upper display. Proceed to Test Step 2. ‘Test Step 2. CHECK THE YELLOW FAULT ALARM INDICATOR A. Check the display of the GSC+ for the yellow fauit 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 programmes 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 selpoinis, seeSysters Operation, “Engina/Generator Setpoint Viewing 0P2.0". In order to reprogram the setpoints, see Systems Operation, “Engine/Generator Programming OP5-0" sToP. © NO - The yellow fault alarm indicator is not iluminated at all. Proceed 10 Test Step 3. Test Step 3, CHECK FOR THE RED FAULT SHI iN INDICATOR A.Check the display area of the GSC+ for the red faut shutdown indicator. Expected Result: The red fault shutdown should be FLASHING. Results: Je 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 's occurring should cause Ihe 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. Troubleshooting Section Repair: Check the appropriate setpoints for correct values. In order to view the setpoints, see System Operation, “Engine/Generator Setpoint Viewing OP2-0", In order to reprogram the selpoints, see System Operation, “Engine/Generator Programming OP5-0". STOP, Test Step 4. CHECK K1 INDICATOR ON GSC+ DISPLAY A. The red fault shutdown indicator is FLASHING and the engine remains running. B. 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 @SC+ 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. jt is unlikely that the GSC+ has failed. Exit this procedure and perform this entire procedure again. It 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. AA. 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,128 Troubleshooting Section Repair, The GSC+ Relay Module ay 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 Modula) - Replace” stor 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, ‘A. Push the emergency stop push button (ESP) Expected Result: ‘The engine should shut down, Resutts: ‘* OK — The engine does shutdown. Proceed 10 Test Step 7 «NOT OK ~The engine does NOT shut down. Repair: The engine ECM made have failed. Refer to Troubleshooting, SENR1003, "35008 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. ‘A. 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 @ short, open connection, of is damaged. Results: © OK ~ The wiring is damaged. Repair: Troubleshoot and repair the wiring. See Generator Set Wiring Diagram in Tasting And Adjusting, “Schematics And Wiring Diagrams” Verify that the repair corrects the probiem. stor. * NOT OK — The wiring is not damaged et all. The engine ECM may have failed, Repair; The engine ECM made have failed. Refer to Troubleshooting, SENR1003, "35008 EPG Engines" or Troubleshooting, RENR2227, “3400 EPG Engines". STOR, iors Engine Does Not Shutdown (for MUI 3306B, 3406C Engines) SMCS Code: 4490-035. SIN: BNS1-Up ‘SIN: 9ES1-Up ‘System Operation Description: The engine does not shut down when a shutdown fault occurs.ed Troubleshooting Section me iF 3 ae @249F 6 Op“ z Esra ps eugeyaowse 7 seteaan 7° 280 SLAVE RELAY Two FUEL ao station 98 Fil Control Reisy For ETR Systems court _ Relae | 3 rary) ALR suurore Seer Bt ie RrauIRES. conitedy a "SBAne PACT Coane Isvavon 09 cess ‘System Schematic For Air Shutott Relay Note: It is critical that GSC+ setpoint P023 is correct tor the engine application, Ensure that setpoint PO23 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 fan engine shutdown.130 ‘Troubleshooting Section * 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, itis @ good idea to check any setpoinis related to that fault. For example, if a genset is not shutting down when an overvoltage fault occurs, meke sure setpoint P104 (Overvoltage shutdown enable) is programmed correctly Is also possible to program the engine ECM 10 override oF ignore certain shutdown faults. See Troubleshooting, SENR1003, “25008 EPG Engines” or Troubleshooting, RENR2227. "9406E 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, it the genset is not shutting down when a high coolant temperature condition occurs, make sure setpoint PO15 (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: GSC+ and a broken or shorted harness wire...In this case, the GSC+ 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 A. Chook 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 s 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 ‘A. Check the display aroa of the GSC+ for the yellow fauit alarm indicator. Expected Result: ‘The yellow fault alarm indicator should be illuminated CONTINUOUSLY. Results: YES - The yellow fault alarm indicator is imirvatogs CONTINUOUSLY. Repair: The GSC+ has been programmed to ‘override the normal shutdown response and the GSC+ treats the condition as an alarm fault, Tha engine will continue to run. In order 10 view the setpoints, see System Operation, “Engine/Generator Setpoint Viewing OP2-0". In ‘order to reprogram the setpoints, see System Operation, “Engine/Generator Programming OPS." STOP, ‘© NO - The yellow fault alarm indicator is not illuminated at all, Proceed to Test Step 3. Test Step 3. CHECK FOR RED FAULT SHUTDOWN INDICATOR. A. Check the display area of the GSC+ fer a red fault shutdown indicator, Expected Result: ‘The red fault shutdown indicator should be FLASHING. Results: © YES — The red fault shutdown indicator is FLASHING and the engine remains running Proceed to Test Step 4,a NO ~All taut indicators are OFF. A problem that is occurring should cause the GSC+ 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 Systern Operation, “Engine/Generator Setpoint Viewing OP2.0°. In order to reprogram the setpoints, 306 System Operation, "Engine/Generator Programming OP5-0" STOP. Test |. CHECK THE SYSTEM BY USING THE ESPB. The engine remains running and the ted fauit shutdown indicator is FLASHING. ‘A. Push the emergency stop push button (ESPB). Expected Result: Tre engine should shut down, Results: * OK ~ The engine does shutdown, The relay module has failed. Repair: Replace the relay module. See Testing ‘And Adjusting, “Relay Module - Replace” STOP, «NOT OK ~ The engine does NOT shut down. Proceed to Test Step 5, Test Step 5. CHECK FOR FUEL CONTROL SOLENOID AND ENGINE PROBLEMS. ‘he engine remains running and the red fault shutdown indicator is FLASHING. A. Remove F14 in the Junction Box. Expected Result: The engine should shut down. Results: * YES - The engine shuts down. Therefore, the fuet control solenoid (FCS) has failed. epair: Replace the fuel control solenoid. Verity that the repair corrects the problem, STOP. 131 Troubleshooting Section © NOT OK ~ The engine continues to run and the red fault shutdown indicator is FLASHING. There is @ problem with the engine. Repair: Refer to the appropriate engine service ‘manual in order to troubleshoot the engine. STOP. owrmn Engine Does Not Shutdown (for MUI 3412C, 3508,3512, 3516 Engines) ‘SMCS Code: 4490-035 SIN: 5PW1-Up; 102 1-Up SIN: BWW1-Up; 1KZ1-Up ‘S/N: 8TW1-Up; 1LZ1-Up_ ‘S/N: 4BZ1-Up; 3FZ1-Up ‘System Operation Description: The engine does not shut down when a shutdown fault occurs,132 ‘Troubleshooting Section ceNggaToR eet conto. tesey ceMegaTOR cokiRo. (esc) SPEED contre, evechnange EQNEROL nae at 2 | frwe poet wehako ReUay Tacupoe ae step Benger’ ‘ohty Mustraton 100 Fuel Control Relay For ETR 8) ° 1 UH |», » L SLL is ie : a aroutrep, | conned t"SBawe FAUCT chanel AZR shuTorr ia ave JeRhat “Box 1465 pred ‘Mustation 101 ‘System Schematic For Ar Shuto Relay (ASA) Note: It is extremely important that GSC+ setpoint P23 is correct for the engine application, Make certain setpoint P023 is programmed correctly for the engine application before continuing with this procedure Note: It is extremely important that GSC+ setpoint O01 is correct for the engine. All generator sets packaged in Larne, Ireland covered by this manual must ALWAYS have this setpoint programmed to 0 ETR fue! solenoid) for both fuel solenoid types {ETR or ETS). ‘There are several possible causes why an engine is rot shutting down when a shutdown fault occurs, Operator Error: The operating conditions of the .generator may not be undersicad by the operator. Ensure that the condition is one thal should cause an engine shutdown,rs ‘+ 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 fauit alarm indicator wil 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, itis a 900d idea to check any setpoints related to that fault. For example, if a generator is not shutting down when an overvoltage fault ‘occurs, make sure setpoint P104Overvoltage shutdown enable) is programmed correctly. ‘ Programming Error - Setpoints Incorrect For ‘Application Or Customer Needs: It is possible to program the GSC+ setpoinis to a vaiue 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 generator is not shutting down when a high Coolant temperature condition occurs, make sure satpoint PO15 (High ‘Water Temperature Shutdown) is correct for the application + Faulty Component: Some examples of fauty components that could prevent the GSC+ from shuiting down the engine are: GSC+ and a broken or shorted harness wire. In this case, the GSC+ will be issuing a command to shut down the engine due to a diagnostic code, bul the engine remains running, Test Step 1. CHECK FOR DIAGNOSTIC CODES ‘A. 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+. sTor. #NO —The GSC+ doas NOT show a diagnostic code on the upper display. Proceed to Test Step 2 133 ‘Troubleshooting Section ‘Test Step 2. CHECK THE YELLOW FAULT ALARM INDICATOR: ‘A. Check the display area of the GSC+ for the yellow fault alarm indicator. Expected Rest The yellow fault alarm indicator should be illuminated CONTINUOUSLY. Results: * YES ~ The yellow fault alarm indicator is illuminated CONTINUOUSLY. Repair: The GSC+ has been programmed to override the normal shutdown response and the GSC+ treats the condition as an alarm fault. The engine will continue to run. In order to view the setpoints, see Systern Operation, “Engine/Generator Setpoint Viewing OP2-0". in order to reprogram the setpaints, sea System Operation, “Engine/Generator Programming OP 5-0" STOP, NO ~The yellow fault aiarm indicator is not illuminated at all. Proceed to Test Step 3. Test Step 3. CHECK FOR RED FAULT SHUTDOWN INDICATOR. ‘A. Check the display area of the GSC+ for the red fault shutdown indicator Expected Result: ‘The red fault shutdown indicator 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+ 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 fa shutdown condition. Repair: Check the appropriate setpoints for correct values. In order to view the setpoints, see Systems Operation, "Engine/Generator Setpoint Viewing OP2-0°, in order to reprogram the setpoints, see Systems Operation, “Engine/Generator Programming OPS-0" STOP,134 ‘Troubleshooting Section Test Step 4. CHECK THE SYSTEM BY USING THE ESPB. The engine remains running and the fault shutdown indicator is FLASHING. ‘A. Push the emergency stop push button (ESPB). Expected Result: The engine should shut down, Resutts: '* OK - The engine does shutdown. The relay module is faulty, Repair: Replace the GSC+ relay module. See Testing and Adjusting, "Relay Module - Replace” Verify that the repair corrects the problem. STOP, ‘* NOT OK ~ The engine does NOT shut down, Proceed to Test Step 5 Test Ste. 5. CHECK GSC+ SETPOINT P001 (FUEL SOLENOID TYPE) ‘The engine remains running after pushing the ESPB. and he red fault shutdown indicator is flashing, ‘A. Check setpoint POO1 (Fuel Solenoid Type). Jn order to view the setpoints, see Systems Operation, “Engine/Generator Setpoint Viewing rg Expected Result: ‘Setpoint POO1 should be programmed to *O” Note: All generator sets packaged in Larne, Ireland, that are covered by this manual must always have this setpoint programmed to *0" (ETR fuel solenoid) fer both fuel solenoid types (ETR or ETS). Results: * YES — Setpoint POO1 is programmed to “0” Proceed to Test Step 6 * NO ~ Setpoint P001 is programmed to “1”. The setpoint is programmed incorrectly. Repair: Reprogram the setpoint 10 @ value of “O" 1 order to reprogram the setpoint, see Systems Speraton,“Engine/Generatr Programming 5.0" STOR. Test Step 6. CHECK VOLTAGE AT THE FUEL CONTROL SOLENOID The engine remains running after pushing the ESPB and the ted faull shutdown indicator is FLASHING, A. At the fuel contro! solenoid, measure the voltage. Expected Result: The voltage measured at the fuel control solenoid should be approximately the same as the nominal battery vottage (+/- 2 volts) Resutts: © OK ~ The battery voltage is correct at the FCS. ‘The FCS has failed or there is a problem with the engine fuel system. Ropair: Refer to the appropriate engine service manual. Replace the FCS or repair the fuel system, STOP. ‘* NOT OK — Battery voltage is not correct at the FCS. The Emergency Fuel Control Relay (EFCR) has failed, Repair: Replace the Emergency Fuel Control Relay (EFCR). Verity that the repair corrects the problem. ‘STOP. varie Engine Does Not Shutdown (for PEEC Engines) ‘SMCS Code: 4490-035 ‘SIN: 4BZ1-Up; 1EZ1-Up ‘System Operation Descripti ‘The engine does not shut down when a shuldown fautt occurs. There are several possible causes why an engine is not shutting down when a shutdown fault occurs:Ero * cenggavon otro erHer Start | Switen! 2) Sena convenver ean), so sof vy 4 ¥ xo [ree | Vf a GB Ph ENGINE is ba prea Iara 102 gonsre7o Sistem Schomatic For Unexpected Shutdown Yale: tis extremely important that GSC+ setpoint F023 is correct for the engine application. Make certain selpoint PO23 is programmed correctly for {te engine application before continuing with this procedure. Note: itis extremely important that GSC+ setpoint, 1 is cortect for the engine. All generator sets .ged in Lame, ireland with serial numbers {ist of S/N’s) must ALWAYS have this setpoint yammed to G (ETR fuel solenoid) for both fuel eid types (ETR or ETS). are several possible causes why an engine is ‘shutting down when a shutdown fault occurs. 135 ‘Troubleshooting Section ‘© 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 favit will be treated as an alarm fault. The YELLOW fault alarm indicator will be FLASHING instead of the RED fault shutdown indicator. I the GSCs is programmed in order to disable a particular faut, there will not be any fault indicators or codes shown on the GSC-. In these cases, it's a good idea to check any setpoints related to that fault. For example, ia genset is not shutting down when an overvoitage fault occurs, make sure setpoint P104(Overvoltage shutdown enable) is programmed correctly. ‘* Programming Error - Setpoints incorrect For Application Or Customer Needs: It is possiole to program the GSC+ setpoints to a value that does not allow the situation to be recognized by the GSC+ as @ 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 PO16 (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: PEEC, GSC», and 4 broken or shorted harness wire.. In this case, the GSC+ or PEEC 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 ‘A. Check the GSC+ for a diagnostic code on the upper display. Expected Resutt: ‘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.136 ‘Troubleshooting Section ‘¢ 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 ‘A. Check the display area of the GSC+ for the yellow fault alarm indicator. Expected Result: ‘The fault alarm indicator should be illuminated ‘CONTINUOUSLY, Results: © YES ~ The fault alarm indicator is illuminated CONTINUOUSLY. Repair: The GSC+ has been programmed to ‘override the normal shutdown response and the GSC+ treats the condition as an alarm faut. The engine will continue to run. In order to view the setpoints, see System Operation, “Engine/Generator Setpoint Viewing OP2-0". In order to reprogram the setooints, see System Operation, “Engine/Generator Programming Ore", STOP, * NO ~The yellow fault alarm indicator is not ‘lluminated at all. Proceed to Test Step 3. Test Step 3. CHECK FOR RED FAULT SHUTDOWN INDICATOR. A. Check the display area of the GSC+ for a red fault shutdown indicator. Expected Resutt: The fed fault shutdown indicator should be FLASHING. Resuits: © 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+ to shut down the engine. Itis 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 eppropriate setpoints for correct values. In order to view the seipoints, see System Operation, “Engina/Generator Setpoint Viewing OP2.0". In order to teprogram the setpoints, see System Operation, “Engine/Generator Programming OP5-0" STOP. Test Step 4. CHECK THE SYSTEM BY USING THE ESPB. ‘The engine remains running and the red fault shutdown indicator is FLASHING A Push the emergency stop push button (ESPB). Expected Result ‘The engine should shut down Results: ¢ OK ~The engine does shutdown, Repair: Replace the PEC or the ESDR. Verify that the repair corrects the problem. STOP. ‘* NOT OK — The engine does NOT shut down, There is an engine problem, Repair: Cheok the fuel shutoff solenoid (FSS) and the engine fuel system. Refer to the appropriate engine service manuals. STOP, evan | GSC Operation Is Erratic ‘SMCS Code: 4490-035 ‘System Operation Description: Fault shutdown indicator on the GSC+ flashes at the rate of four to five times per second (4 10 5 H2). The displays of the GSC+ may not be responding ‘The GSC+ does not respond to any position of the engine control switch (ECS). peThis is an internal fault of the GSC+ that can be lemporary or permanent. The fault is caused by @ component failure in the GSC+. Also, the fauit may be caused by severe electromagnetic fields oF radio frequency interference. The relays in the relay module are automatically turned off when this fault occurs. The effect of this fault on the engine depends on the type of fuel system. ‘* For engines with 8290 governor, the engine runs atidlo speed, The emergency stop push button (ESPB) will shut down the engine. «For engines with a mechanical governor, the engine will shut down, RESET THE GSC+ ‘A. Tum the ECS to OFF/RESET. If the GSC+ does not power down, remove the jumper that connects terminals 6 and 10 on the ECS. B. Turn the ECS to STOP. Expected Result: ‘The GSC+ should power up with a normal display and the GSC+ should respand to the ECS Results: © OK — The GSC+ is operating normally. Repair: The GSC+ will need to be replaced it the problem reoccurs. STOP. = NOT OK ~The GSC+ does NOT operate correctly and the fault shutdown indicator stil flashes at the fata of four to five times per second (4 to 5 Hz). Ropair: The GSC+ has failed. Replace the GSC+. See Testing And Adjusting, “EMCP Electronic Contral (Generator Set ) - Replace” STOP. 137 . ‘Troubleshooting Section wrseseue Display of Voltage or Current Is Zero (for MUI 3306B, 3406C Engines) ‘SMCS Code: 4490-035 ‘SIN: BNS1-Up. ‘SIN: 9ES1-Up ‘System Operation Description: Zero volts or zero amperes are showing on the display of the GSC+ for one or more AC phases. This is showing while the genset is running and the load is connected.138 ‘Troubleshooting Section. * — $ G 2 ca » a A rae OD (Teo fo jo fo a so) so O51 % 68 O+ (aTB+) (ouassts ero) (ic oReuno) oa ay 1 “sy eset (wa ani AC TRANSFORMER BOX+ mea ue Np $F ese-6 ae 1) je cse-4 cra 0 ozngaaron 165 eset (ve tm conten, + station 103 ‘Systom Schematic For AC Tranetormer Box + |A.Wye Connection Is Shown For The Generator FLU} When the engine-generator, or any source to which the engine-generator is synchronized to, is operating, voltages up to GOOV are present In the control panel. Do not short these terminal with line voltage to ground with any part of the body or any conduc tive material. Loss of life or injury could result from electrieal shock or Injury from molten met- see Test Step 1. THE PROBLEM IS WITH AC VOLTAGE OR THE PROBLEM IS WITH AC CURRENT. A. Determine if the problem is with AC voltage or with AC current, Check the display of the GSC+ while the genset is runing and the load is connected. AC VOLTAGE — Zero volts are showing on the display of the GSC+ for one or more AC phases. Proceed to Test Step 2.* AC CURRENT ~ Zero. ampotos ere showing on the display of the GSC+ for one or more AC phases. Proceed to Test Step 7. Test Step 2. CHECK THE FUSES. ‘A. Check the three {uses on the AC transformer box + (ATB+). Expected Result: ‘The fuses should not be open. Results: © OK ~ The fuses are not open. Proceed to Test Step 3. ‘* NOT OK ~ One or mote of the fuses are open. pair: One or more of the fuses are open. Check for a shorted component or damaged wiring. Troubleshoot and! repair the problem. See the Generator Set Wiring Diagram in Testing And Agjusting, “Schematics And Wiring Diagrams”. ‘ter the problem has been repaired, replace the fuses, STOP, Test Step 3. CHECK THE GENERATOR OUTPI ‘A. Open the circuit breaker or remove the load. 8 Start the engine and run the genset. C. Measure the voltage between all three fuses on the ATB+. Expected Result: The line to line voltage should measure the rated votage of the genset, Results: * OK — The voltages are correct and the problem remains. Proceed to Test Step 4. "NOT OK — One or more of the voltages are NOT const. Repair: The wiring or the connections are damaged. Check for damaged wiring between the ATB+ and the bus. See the Generator ‘Set Wiring Diagram in Testing And Adjusting, “Schematics And Wiring Diagrams”, Also, check the electrical connections at the terminal of the ATBs . See Testing And Adjusting, “Electrical Connector - inspect, ‘STOP, 139 ‘Troubleshooting Section Test Step 4. CHECK THE CONNECTIONS A, Shut down the engine, B. Check the harness connector and the terminals, of the ATB+ ©. Check the GSC+ harness connector, See Testing And Adjusting, "Electrical Connector - inspect”. D. Check for one or more damaged wires between the ATB+ and the GSC+. See the Generator Set Wiring Diagram in Testing And Adjusting, “Schematics And Wiring Diagrams". Expected Result: The wiring and the connactors should have been ‘good. Results: # OK — NO problem was found with the connectors or with the wiring. Proceed to Test Step 5. © NOT OK ~The problem was with the connectors ‘of with the wiring. Repair: Repair the connectors or replace the wiring hares. STOP, Test Ste THE Al ‘A. Remove the GSC+ harness connector from the ATB+. CHECK THE OUTPUTS OF B. At the terminal of the ATB+, measure the resistance between the following terminals: terminal J1-7 to terminal J1-1, terminal J1-7 to terminal J7-2, and terminal J1-7 to terminal J1-3 Expected Result: Each of the resistance measurements should be 7.0 + 1.0 Onms, Results: '* OK ~ Each of the resistance measurements is 7.0 = 1.0 Ohms. Proceed to Test Step 6. ‘* NOT OK ~ One or more of the resistance measurements is NOT 7.0 + 1.0 Ohms. Repair: The ATS+ has failed. Replace the ATB+. ‘See Testing and Adjusting Section, "EMCP Electronic Control (AC Transformer Box} - Replace’. STOP,440 Troubleshooting Section Test Step 6. CHECK THE INPUTS OF THE ATB+ ‘A. Remove the three fuses on the ATB#: F11, F12, and FA3 B. At the terminal of the ATB+, measure the resistance between the following terminals: terminal T11 to terminal H21, terminal T12 to terminal H21, and terminal T13 to terminal H21 Expected Result: Each of the resistance measurements should be 4,050 100 Ohms. Results: * OK — Each of the resistance measurements is 4,050 + 100 Ohms. Repair: The GSO+ 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. ‘© NOT OK — One or more of the resistance measurements was NOT 1,050 = 100 Ohms. Repair: The ATB+ has failed. Replace the ATB+, See Testing and Adjusting Section, “EMCP Electronic Control (AC Transformer Box) ~ Replace”. STOP. Test Step 7. CHECK THE CURRENT TRANSFORMERS A. Shut down the engine B. At terminals 5%, 52, and 53 of the ATB-, disconnect only the wires that ead away from the ATB+. These disconnected wires go to the current transformers. These current transformers are CT1, CT2, and CTS. , Measure the resistance from terminal 50 to each of the disconnected wires. Expected Result: ‘The resistance should be approximately § Ohms. Results: '* OK — The resistances are approximately 5 Ohms, ‘Therefore, the current transformers are good. Proceed to Test Step 8. ¢ NOT OK ~ One or more of the resistance measurements are NOT correct. A related current transformer or related wire is open. Ropair: Replace the open current transformer or repair the wiring. See the Generator Set Wiring Diagram in Testing And Adjusting, “Schematics ‘And Wiring Diagrams". STOP. Test Step 8. CHECK THE OUTPUTS OF THE ATB+ A. Shut down the engine. 'B. Remove the hamess connector from the GSC+ ©. At the hamess connector of the GSC+ , measure the resistance between the following contacts: contact 4 to contact 16, contact § to contact 18, ‘and contact 6 to contact 16, Be sure to allow each measurement to stabilize. Expected Result: Each of the three resistances should be 120 + 20 ‘Ohms. Results: © OK ~ Each of the three resistances is 120 + 20 Ohms. Proceed to Test Step 10. ‘® NOT OK - One or more of the resistance measurements are NOT correct, Proceed to Test Step 9. ‘Test Step 9. CHECK THE GSC+ HARNESS: CONNECTOR ‘A. Remove the GSC+ hamess from the ATB+. B. Check the resistance of the wires in the GSC+ amass for an open wire. See the Generator ‘Sot Wiring Diagram in Testing And Adjusting, "Schematics And Wiring Diagrams” Expected Resutt: ‘The wires in the GSC+ hamess should measure less than § Ohms.Repair: The ATB+ has failed. Replace the ATB+. See the Testing and Adjusting Section, *EMPC Electronic Control (AC Transformer Box) - Replace”. sToR, * NOT OK — The wires in the GSC+ harness do NOT measure less than 5 Ohms. Repair: Repair the wiring or replace the GSC+ hamess. Verify that the repairs fixed the problem, STOP. Test Step 10. CHECK THE INPUTS OF THE ATB+ ‘A. The wires that were previously disconnected from terminals 51, 82, and 53 will remain disconnected. The only wires which are comected to these terminals should lead ito 6 ATB+ B. At the terminal strip of the ATB+, measure the resistance between the following terminals: terminal $1 to terminal 50, terminal 52 to terminal 50, and terminal 53 to terminal 50. Expected Result: All the resistance measurements should read less than 1 Ohm, Results: + OK ~All the resistance measurements do read fess than 1 Ohm, Repair: The GSC+ may have felled. It is unlikely that the GSC+ has failed. Exit this procedure and perform this entire procedure again. It {he problem remains, replace the GSC+. See Testing And Adjusting, “EMCP Electronic Control {Generator Set) - Replace” STOR, }s NOT OK - One or more of the resistance measurements are NOT correct. Regal: The ATB- has faled, Replace the +. See the Testing and Adjusting Section, *EMPC Electronic Control (AC Transformer Box) - Replace”. STOR, 141 : Troubleshooting Section Results: ‘orsronst * OK ~The wires in the GSC+ hamess measure Display of Voltage or Current tess than 5 Ohms. Is Zero (for MUI 3412C, 3508, 3512, 3516 and EUI and PEEC Engines) ‘SMCS Code: 4490-035 ‘S/N: 4821-Up; 1EZ1-Up ‘S/N: SKW1-Up: 1FZ1-Up ‘SIN: 6GW1-Up; 1GZ1-Up SN: BNW1-Up; 1HZ1-Up ‘S/N: 5PW1-Up; 1JZ1-Up ‘S/N: 6WW1-Up; 1KZ1-Up- SIN: 8TW1-Up; 1L21-Up SIN: 8AZ1-Up; 1MZ1-Up ‘SM: 4821-Up; 3FZ1-Up ‘System Operation Description: Zero volts or zeto amperes are snowing on the display of the GSC+ for one or more AC phases. ‘This is showing while the genset is running and the load is connected,142 Troubleshooting Section : _ ~ i 2 (& Jos z = 5 PO7O 7S PO}OPS }2 8 ‘® | be bebade (ATBH) AC TRANSFORMER BOX+ ‘950-17 {OHASSIS.eROUNDY (e5c-18 (RE oROUND) ‘se-8 (06 18) ese-8 (U9 18) osc-4 GA aN) fescmtz «ve aM ‘scm (¥8 Om) scm10 (uA aH lesen) cenggaror Se stration 104 ‘System Schematic For An AC Transformer Box (ATB#) ‘Aye Connection Is Shown For The Generatr. 7 eG ics When the engine-generator, or any source to which the engine-generator Is synchronized to, Is. ‘operating, voltages up to GOOV are present in the control panel. Do not short these terminal with line voltage to ‘ground with any part of the body or any conduc- tive material. Loss of Iife or injury could result from electrical shock or injury from molten met- al. oo Test Step 1. THE PROBLEM IS WITH AC VOLTAGE OR THE PROBLEM IS WITH AC. CURRENT. A. Determine if the problem is with AC voltage ‘or with AC current. Check the display of the GSC+ while the genset is running and the load is comnected. Results: © AC VOLTAGE — Zero volts are showing on the display of the GSC+ for one or more AC phases. Proceed to Test Step 2+ AC. CURRENT ~ Zoro amperes are showing on the display of the GSC+ for one or more AC phases. Proceed to Test Step 7. Test Step 2. CHECK THE FUSES. ‘A. Check the three fuses on the AC transformer box + (TBs). Expected Result: ‘The luses should not be open. Results: © OK - The fuses are not open, Proceed to Test Step 3. ¢ NOT OK — One or more of the fuses are open. Repair: One or more of the fuses are open, Check for a shorted component or damaged wiring. Toubleshoot and repair the problem, See the Generator Set Winng Diagram in Testing And Adjusting, “Schematics And Wiring Diagrams" Aer the problem has been repaired, replace the fuses, STOP. Test Step 3. CHECK THE GENERATOR outeue ‘A. Open the circuit breaker or remove the load. B, Start the engine and run the genset. . Measure the voltage between all three fuses on the ATE, Expected Result: The line to line voltage should measure the rated voltage of the genset. Results: © OK ~The voltages are correct and the problem remains. Proceed to Test Step 4. ‘* NOT OK — One or more of the voltages are NOT correct. Repair: The wiring or the connections are damaged. Check for damaged wiring between the ATB+ and the bus. See the Generator ‘Set Wiring Diagram in Testing And Adjusting, “Schematics And Wiring Diagrams”. Also, check the electrical connections at the terminal of the ATB+ . See Testing And Adjusting, "Electrical Connector - Inspect” STOP. ta ‘Troubleshooting Section Test Step 4, CHECK THE CONNECTIONS A. Shut down the engine, B. Check the harness connector and the terminals of the ATB+. ©. Check the GSC+ harness connector. See Testing And Adjusting, “Electrical Connector - Inspect’ D. Chock for one or more damaged wires between the ATB+ and the GSC+. See the Generator Set Wiring Diagram in Testing And Adjusting, *Schematics And Wiring Diagrams". Expected Result: ‘The wiring and the connectors should have been good. Resutts: *¢ OK — NO problem was found with the connectors or with the wiring. Proceed to Test Step 5. ‘* NOT OK ~The problem was with the connectors ‘or with the wiring Repair: Repair the connectors or replace the wiring harness. STOP. Test Step 5. CHECK THE OUTPUTS OF THE ATB+ ‘A. Remove the GSC+ harness connecior from the ATB+. B. At the terminat of the ATB+ , measure the resistance between the following terminals: terminal J1-7 to terminal J1-1, terminal J1-7 to terminal J1-2, and terminal J1.7 to terminal J1-3 Expected Result: Each of the resistance measurements should be 7.0 # 1.0 Ohms. Results: © OK ~ Each of the resistance measurements is 7.0, # 1.0 Ohms. Proceed to Test Step 6. * NOT OK - One or more of the resistance measurements is NOT 7.0 + 1.0 Ohms. Ropair: The ATB+ has failed. Replace the ATB+. See Testing and Adjusting Section, “EMCP. Electronic Control (AC Transformer Box) - Replace” STOP. —144 ‘Troubleshooting Section Test Step 6. CHECK THE INPUTS OF THE ATB+ A. Remove the three fuses on the ATB+: F11, F12, and F13 B. At the terminal of the ATB+, measure the resistance between the following terminals: terminal T11 to terminal H21, terminal T12 10 terminal H21, and terminal T13 to termina) H21 Expected Result: Each of the resistance measurements should be 4,050 + 100 Ohms. Results: * OK —Each of the resistance measurements is. 4,050 + 100 Ohms. Repair: The GSC+ may have tated. It is unlikely that the GSC+ has failed. Exit this procedure and pertorm this entire procedure again. It the problem remains, replace the GSC+. See Testing And Adjusting, "EMCP Electronic Control (Generator Set) - Replace’. STOP, ® NOT OK - One of more of the resistance measurements was NOT 1,050 + 100 Ohms. Repair: The ATB+ has failed. Rep'ace the ATB+. See Testing and Adjusting Section, “EMCP Electronic Contro! (AC Transformer Box} - Replace’, stor. Test Step 7. CHECK THE CURRENT TRANSFORMERS A. Shut down the engine. B. At terminals 51, 52, and 53 of the ATB+, disconnect only the wires that iead away from the ATB+. These disconnected wires go to the current transformers, These current transformers are CT1, CT2, ang C73. C. Measure the resistance from terminal 60 to each of the disconnected wires. Expected Result: The resistance should be approximately 5 Ohms. Results: # OK — The resistanoas are approximately 5 Ohms. Therefore, the current transformers are good Proceed to Test Step &. ‘* NOT OK - One or more of the resistance measurements are NOT correct. A related current transformer or related wire is open. Repair: Replace the open current transformer or repair the wiring. See the Generator Set Wiring Diagram in Testing And Adjusting, “Schematics ‘And Wiring Diagrams” STOP. Test Step 8. CHECK THE OUTPUTS OF THE ATB+ A. Shut down the engine. B. Remove the harness connector from the GSC+. . At the hamess connector of the GSC+ . measure the resistance between the following contacts: contact 4 to contact 16, contact 5 to contact 16, and contact 6 to contact 18. Be sure to allow each measurement to stabilize. Expected Result: Each of the three resistances should be 120 + 20 Ohms. Resul * OK = Each of the three resistances is 120 + 20 Ohms. Proceed to Test Step 10. ‘* NOT OK ~ One or more of the resistance measurements are NOT correct, Proceed to Test Step 9. Test Step 9. CHECK THE GSC+ HARNESS: CONNECTOR ‘A. Remove the GSC+ harass from the ATB+. B. Check the resistance of the wites in the GSC+ harness for an open wire. See the Generator Set Wiring Diagram in Testing And. Adjusting, “Schematics And Wiring Diagrams”. Expected Result: The wires in the GSC+ hamess should measure legs than 5 Ohms.Results: + OK ~The wires in the GSC+ harness measure ess than 5 Ohms. Repair: The ATB+ has failed. Replace the ATB+. See the Testing and Adjusting Section, "EMPC Electronic Control (AC Transformer Box) - Replace’. STOR * NOT OK - The wires in the GSC+ harness do NOT measure less than 5 Ohms. Repair: Repair the wiring or replace the GSC+ hamess. Verify that the repairs fixed the problem, STOP, Test Step 10. CHECK THE INPUTS OF THE ATB+ ‘A. The wires that were previously disconnected from terminals 51, 52, and 53 will remain disconnected. The only wires which are connected to these terminals should lead into the ATB+. B. At the terminal strip of the ATB+, measure the resistance between the following terminals: terminal 51 to terminal 50, termina! 62 ta terminal 50, and terminal 53 to terminal 50. Expected Result: All the resistance measurements should read less than 1 Ohm. Results: + 0K — All the resistance measurements do read less than 1 Ohm. Repalr: The GSC+ may have failed. I is unlicely that the GSC+ has failed. Exit this procedure. and perform this entire procedure again. If the problem remains, repiace the GSC+. See Testing And Adjusting, “EMCP Electronic Controt (Generator Set) - Replace’. STOP. «NOT OK - One or more of the resistance measurements are NOT correct. Repair: The ATB+ has failed. Replace the AIB+. See the Testing and Adjusting Section, “EMPC Electronic Control (AC Transformer Box) - Replace’ STOP. ——™ Troubleshooting Section