Troubleshooting The ETR Full Protective System (OP, WT, OS)

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Testing and Adjusting

Electric Protection System Energize-To-Run For Generator Set, Industrial and Marine
Diesel Engines
Media Number -RENR1377-03 Publication Date -01/11/2002 Date Updated -19/11/2002
i01080231
Troubleshooting the ETR Full Protective System (OP, WT,

OS)
SMCS - 7400-035
Problem 1
The engine cranks but the engine does not start.
1. Check the engine fuel system.
a. Crank the engine.
b. Observe the action of the fuel rack, the governor, and the position of the air shutoff
valve, if equipped.
c. If a 2301A Electric Governor is installed, measure the voltage that is supplied to the
governor.
Result
The fuel rack and the governor move in the FUEL ON direction. If equipped, the
air shutoff lever is in the RUN position.
The problem is in the engine or in the fuel system. Refer to the engine Service Manual.
STOP.
The fuel rack does not move. The governor does not move in the FUEL ON
direction.
The start/stop switch was not in the START position. Go to Step 2.
The air shutoff valve is in the shutoff position. If equipped, the air shutoff
solenoid is in the shutoff position. One or both of the conditions may be possible.
Manually reset the air shutoff lever. Go to Step 5 if the lever or the solenoid cannot be
reset or if the solenoid trips on each attempt to start the engine.
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A 2301A Electric Governor is installed and the supply voltage is greater than 15
volts.
The problem is in the governor or the actuator system. Refer to the 2301A Electric
Governor Service Manual, SENR3585. STOP.
A 2301A Electric Governor is installed and the supply voltage is less than 15
volts.
The problem is in the wiring to the 2301A Electric Governor. Go to Step 3.
2. Check the slave relay (SR1) and the fuel rack.
a. Connect a jumper with a 20 amp capacity between terminals (TS-11) and (TS-30) of the
junction box.
b. Measure the voltage at terminal (TS-11) of the junction box.
c. Reset the circuit breaker (CB7).
d. Crank the engine. Stop the engine with the emergency stop switch if trouble occurs.
e. Remove the jumper when the test is completed.
Result
The engine starts and the engine runs.
The slave relay (SR1) is not energizing the shutoff solenoid. Go to Step 3.
The engine does not start.
The shutoff solenoid is stuck or the fuel rack is stuck in the shutoff position. If there is
no voltage at terminal (TS-11), the circuit breaker (CB7) may be open. Reset the circuit
breaker or replace the circuit breaker. Find the source of the problem and correct the
source of the problem. STOP.
3. Check the slave relay (SR1).
a. Connect a jumper between terminals (TS-14) and (TS-24) of the junction box.
b. Crank the engine. Stop the engine with the emergency stop switch, if trouble occurs.
c. Remove the jumper when the test is completed.
Result
The (SR1) is not faulty. Go to Step 4.
Contacts (SR-30) and (SR-87a) of (SR1) that are normally open have been shorted and
the fuel shutoff solenoid is not being energized. If a 2301A Electric Governor is
installed, contacts (SR-30) and (SR-87a) of (SR1) that are normally closed are open or
the wiring to the 2301A Electric Governor is faulty. Replace the (SR1) or repair the
wiring problem. Refer to Testing and Adjusting, "Slave Relay Test". STOP.
4. Check the protection components.
b. Ensure that the emergency stop switch (ES) has been reset and that the start/stop switch
is in the RUN position.
c. Crank the engine. Stop the engine with the emergency stop switch if trouble occurs.
Note: The engine must have oil pressure when the engine is cranking in order for this
test to be valid.
d. Remove the jumper when the test is completed.
Result
The problem is in the switches for the oil pressure or in the electronic speed switch
(ESS). Go to Step 7.
The problem is not in the protection components or in the ESS. Go to Step 8.
5. Check the overspeed setting of the electronic speed switch and the diode (D2).
a. Ensure that the push button for the emergency stop (ES) has been reset.
b. Check the indicator lamp for the electronic speed switch (ESS). Press the reset button if
the lamp is turned on.
Result
The engine starts and the engine runs after the ES or the ESS has been reset.
The problem has been solved. STOP.
The engine starts and the engine runs without resetting the ES or the ESS.
The problem is intermittent. Check the mechanical condition of the latch mechanism in
the air shutoff control, if equipped. STOP.
If equipped, the air shutoff valve closes before the engine is cranked.
Go to Step 6.
If equipped, the air shutoff valve closes and the engine overspeed lamp turns on
while the engine is cranked or shortly after the engine has been started.
The engine is exceeding the overspeed setting of the ESS. Recalibrate the ESS. Refer to
Testing and Adjusting, "Overspeed Calibration".
If equipped, the air shutoff valve closes and the engine overspeed lamp does not
turn on while the engine is cranked or shortly after the engine is started.
The ES may have a short or the system wiring is incorrect. Check the ES and the wiring.
Also check that the contacts for the engine overspeed on the ESS are not shorted. Repair
the faulty components or replace the faulty components. STOP.
a. Disconnect the wire at terminal (TS-25) on the terminal strip in the junction box. The
wire runs from terminal (SR2-87) of the slave relay (SR2), if equipped.
b. Crank the engine.
Result
The problem is in the slave relay (SR2) or the wiring to the (SR2). Refer to Testing and
Adjusting, "Diode Test". Go to Step 7.
If equipped, the air shutoff valve closes while the engine is cranking or
immediately after the engine is started.
A mechanical problem exists in the latch mechanism of the air shutoff control. Repair
the problem. STOP.
7. Check the oil pressure step switch of the ESS.
a. Connect a jumper between terminals (OPS1-1) and (OPS1-2) of the oil pressure switch
(OPS1).
b. Start the engine.
Note: The engine must have oil pressure when the engine is cranking in order for this
test to be valid.
c. Remove the jumper when the test is completed. Repeat the procedure for (OPS2).
Result
The engine starts and the engine runs when the jumper is connected across the
terminals of (OPS1).
Replace oil pressure switch (OPS1). Refer to Testing and Adjusting, "Engine Oil
Pressure Switch Test".
The engine does not start and the engine does not run at low idle.
The ESS is faulty if the contacts of (OPS1) are open. The contacts are normally closed.
Check the ESS and the wiring to the ESS. Refer to Testing and Adjusting, "Oil Step
Speed Calibration". Check terminals (SSS-10) and (SSS-11) of the start/stop switch.
Check the connections to the terminals for the START position on the start/stop switch.
The switch may not be making contact across the terminals. STOP.
The engine starts and the engine runs when the jumper is connected across
(OPS2).
The speed setting on the oil pressure step switch (OPSS) is not correct. Refer to Testing
and Adjusting, "Oil Step Speed Calibration".
8. Check the water temperature contactor switch (WTS) and the start/stop switch.
a. Install a jumper between terminals (TS-2) and (TS-3). Also install a jumper between
terminals (TS-4) and (TS-5) of the junction box.
c. Remove the jumpers when the test is completed.
Result
The contacts of the WTS are closed across terminals (WTS-1) and (WTS-2) because the
coolant temperature is excessive.
The start/stop switch is not making contact across the contacts for the START position.
The start/stop switch is in the STOP position.
Repair the faulty components.
Go to Step 9.
9. Check the circuit breaker (CB5) and the crank terminate switch of the ESS.
a. Measure the voltage at terminals (TS-2) and (TS-24) of the junction box. Also measure
the voltage at terminals (ESS-12) and (ESS-9) of the ESS. Measure the voltages before
you crank the engine and while you crank the engine.
Result
The voltage is below 10 volts.
The circuit breaker (CB5) is open or there is no power to the junction box. Reset (CB5)
or replace the circuit breaker. Check the wiring. STOP.
Before you crank the engine, the voltage at terminal (TS-24) is above 10 volts and
the voltage at terminal (ESS-12) is below 10 volts.
The crank terminate adjustment is not correct. Refer to Testing and Adjusting, "Crank
Terminate Speed Calibration". STOP.
Before you crank the engine, the voltage at terminal (ESS-12) is above 10 volts.
The voltage at terminal (ESS-9) is less than the voltage at terminal (ESS-12) by 2
volts or more.
The diode (D3) is faulty or the diode has been shorted out. Refer to Testing and
Adjusting, "Diode Test".
While you crank the engine, the voltage at terminal (ESS-12) is above 10 volts
and the voltage at terminal (ESS-9) decreases when the crank terminate speed is
reached.
Note: When the crank terminate speed is reached, the starting motor will stop cranking.
The voltage at terminal (ESS-9) will show a noticeable decrease if a component of the
circuit is faulty.
The overspeed switch is tripped and the switch must be reset. The ESS may also be
faulty. Refer to Testing and Adjusting, "Overspeed Verification Test". The diode (D2)
may also be faulty. Refer to Testing and Adjusting, "Diode Test".
The starting motor does not stop cranking because the crank terminate speed is
not reached.
Go to the next result.
The voltage at terminals (TS-24) and (ESS-12) is above 10 volts. The voltage at
terminal (ESS-9) is within 2 volts of the voltage at terminals (TS-24) and (ESS-
12). The voltage at terminal (TS-2) is zero or less than the voltage at terminal
(ESS-9).
The emergency stop switch (ES) is in the shutoff position or the ES is faulty. Reset the
ES or repair the ES. STOP.
The voltage at terminals (TS-24) and (ESS-12) is above 10 volts and the voltage
at terminals (TS-2) and (ESS-9) is within 2 volts of the voltage at terminals (TS-
24) and (ESS-12).
The start/stop switch is in the STOP position or the switch is faulty. Move the switch to
the RUN position or replace the switch. STOP.
Problem 2
The engine does not crank.
1. Check the start/stop switch.
a. Ensure that the emergency stop switch (ES) has been reset.
b. Connect a switch with a 2 amp capacity between terminals (TS-21) and (TS-26) of the
junction box.
c. Close the switch momentarily, but do not start the engine.
d. Disconnect the switch after the test is completed.
Results
The engine cranks.
The start/stop switch is faulty or the wiring to the switch is faulty. The circuit breaker
(CB2) may also need to be reset. Replace the switch or repair the wiring, if necessary.
Go to Step 2.
2. Check the electronic speed switch and the emergency stop switch.
a. Connect a switch with a 2 amp capacity between terminals (TS-26) and (TS-24) of the
junction box.
b. Close the switch momentarily but do not start the engine.
c. Disconnect the switch after the test is completed.
Result
The engine cranks.
The electronic speed switch (ESS) or the emergency stop switch (ES) is faulty. Go to
Step 3.
Reset the circuit breaker (CB5) and repeat Step 2. If the engine does not crank go to
Step 4.
3. Check the emergency stop switch and the electronic speed switch.
a. Connect a switch with a 2 amp capacity between terminals (ESS-12) and (TS-26) of the
junction box.
b. Close the switch momentarily, but do not start the engine.
c. Disconnect the switch after the test is completed.
Result
The engine cranks.
The ES or the wiring to the ES is faulty. Replace the ES or repair the wiring. STOP.
The ESS or the wiring to the ESS is faulty. Go to Step 5.
4. Check the components of the starting system.
a. Check the voltage at terminal (TS-24) of the junction box.
Result
The voltage is low. Low voltage is between 1 volt and 20 volts.
Charge the battery or repair the loose connections between the battery cable terminal
and the battery. STOP.
The voltage is above 20 volts.
The magnetic switch (MS), the pinion solenoid (PS), or the starting motor (SM) is
faulty. The circuit breaker (CB2) may need to be reset. Reset the circuit breaker and
repair the component that is faulty.
The voltage is zero (less than 1 volt).
The circuit breaker (CB5) is being overloaded or the circuit breaker is faulty. Repair the
short circuit or replace the circuit breaker. STOP.
5. Check the electronic speed switch.
a. Connect a switch with a 2 amp capacity between terminals (ESS-12) and (TS-26) of the
junction box.
b. Close the switch momentarily, but do not start the engine.
Result
The engine cranks.
The ESS is faulty. Repair the ESS or replace the ESS. STOP.
The wiring to the ESS is faulty. Repair the wiring to the ESS. STOP.
Problem 3
The engine starts and shutdown occurs immediately, or engine cranking terminates.
1. Check the switches on the protection system.
a. Wait for 70 seconds after the engine has shutdown before you attempt to restart the
engine. If an electric starting motor or a DC-actuated starting motor is equipped with the
engine, immediate restarting of the engine can be enabled.
Enable the immediate restart of an electric starting motor by removing the jumper that is
between terminals (TS-27) and (TS-28).
Enable the immediate restart of a DC-actuated starting motor by removing the jumper
that is between terminals (TS-27) and (TS-28) of the junction box. Install the jumper
between terminals (TS-26) and (TS-27) of the junction box.
b. Ensure that the engine lubrication system is filled to the correct level with oil.
c. Ensure that the oil pressure increases when the engine is cranking.
d. Connect a jumper between terminals (TS-9) and (TS-14) of the junction box.
e. Start the engine.
f. Remove the jumper when the test is completed.
Result
One of the oil pressure switches is causing the problem. Go to Step 7 of "Problem 1".
The engine cranking terminates or shutdown of the engine occurs immediately

after starting.
Go to Step 2.
c. Measure the voltage at terminal (TS-14).
d. Observe the air shutoff valve, if equipped. Check if the air shutoff valve moves into the
shutoff position.
e. Remove the jumper when the test is completed.
Result
The air shutoff valve moves to the shutoff position.
Go to Step 5 of "Problem 1".
A voltage appears on terminal (TS-14) when the engine stops. The air shutoff
valve does not move to the shutoff position.
A voltage does not appear at terminal (TS-14) when engine shutdown occurs.
Media Search - RENR1377 - Electric Protection System Energize-To-Run For Gen... Page 10 of 14
The electronic speed switch (ESS) is faulty. Refer to Testing and Adjusting, "Crank
Terminate Speed Calibration". Also check the diode (D2) and check the wiring.
Problem 4
The starting motor remains engaged or the starting motor continues to run after the
engine is running.
1. Check the components of the starting circuit.
a. Measure the voltages at terminal (TS-26) of the junction box and at terminal (ESS-12)
of the electronic speed switch while the engine is running.
Result
The voltage at both terminals is zero volts.
The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic
switch (MS). Repair the faulty component. STOP.
The voltage at terminal (ESS-12) is between 15 volts and 32 volts. The voltage at
terminal (TS-26) is above 15 volts or below 15 volts but not zero volts.
The contacts for the crank terminate (CT) switch of the electronic speed switch (ESS) do
not open. Refer to Testing and Adjusting, "Crank Terminate Speed Calibration". If the
ESS is not faulty, check diode (D3). Refer to Testing and Adjusting, "Diode Test".
The voltage at both terminals is between 15 volts and 32 volts.
The voltage at the terminals is greater than zero volts. During the normal operation of
the start/stop switch, the start/stop switch opens across the contacts of the START
position. Also, the start/stop switch closes across the contacts of the RUN position. The
switch closes when the toggle or the lever of the switch moves from the START
position to the RUN position. Repair the switch if the voltage is zero.
The voltage at terminal (ESS-12) is not zero.
The CT contacts of the ESS are not opening. Refer to Testing and Adjusting, "Crank
Terminate Speed Calibration".
Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
1. Check the overspeed setting on the electronic speed switch (ESS).
a. Observe the indicator lamp on the ESS.
b. Reset the air shutoff lever, if equipped.
Result
The indicator lamp on the ESS is turned on.
Overspeed is indicated as the cause of the engine shutdown. Press the "RESET" button
of the ESS. Find the cause of the overspeed. Refer to Testing and Adjusting, "Overspeed
Verification Test" and Testing and Adjusting, "Overspeed Calibration". If the overspeed
is adjusted properly and the problem persists, check the shielded cable. Only the shield
should be connected to terminal 2 on the ESS. STOP.
The indicator lamp is turned off.
Go to Step 2.
2. Check the oil pressure switches.
Result
The problem is in the oil pressure switches. Go to Step 7 of "Problem 1".
The engine starts but engine shutdown occurs immediately.
The engine starts and the engine runs but engine shutdown occurs after the engine
runs for more than 3 minutes.
Go to Step 3.
The engine cranks but the engine does not start.
Note: If the water temperature contactor switch causes overheating go to Step 8 of

"Problem 1". If the water temperature contactor switch is not the problem, go to Step 1of
"Problem 1".
a. Disconnect the jumper from terminals (TS-9) and (TD-14).
b. Connect a jumper between terminals (TS-14) and (TD-24).
Result
Go to Step 4.
Engine shutdown still occurs.
The contacts of SR1 periodically open. The problem may also be with the governor or
the fuel supply to the engine. Refer to the Engine Service Manual. If a 2301A Electric
Governor is used, the SR1 contacts may be opening. Refer to 2301A Electric Governor
Service Manual, SENR3585. Test SR1. Refer to Testing and Adjusting, "Slave Relay
Test".
4. Check the continuity and the wiring of the protection switches and the start/stop switches.
Result
Power to the start/stop switch, the water temperature contactor switch, or a connection
to the components is periodically faulty. Check the continuity of the switches and repair
any of the loose connections. STOP.
Engine shutdown occurs after several minutes.
The operation of the start/stop switch, the contacts of the ESS, the diode (D2), or the
wiring to the contacts is periodically faulty. Check the switches for continuity and repair
any of the loose connections. STOP.
Problem 6
Engine shutdown does not occur when a fault is detected.
a. Disconnect the wire that is between terminals (SR1-85) and (TS-14). Insulate the end of
the wire.
Result
(SR1) is shorted or stuck in the closed position. Refer to Testing and Adjusting, "Slave
Relay Test". The fuel solenoid (FS) may also be stuck in the RUN position. STOP.
The engine cranks but the engine will not start.
Go to Step 2.
2. Check the protection switches and the crank terminate switch of the electronic speed switch.
a. Reset circuit breakers (CB7) and (CB6).
b. Start the engine and run the engine at low idle.
Note: Disconnect the switches one at a time in order to simulate a fault.
c. Disconnect the oil pressure switch (OPS1).
d. Disconnect the oil pressure switch (OPS2), if equipped.
e. Disconnect the water temperature contactor switch (WTS).
f. Refer to Testing and Adjusting, "Overspeed Verification Test" in order to test the
overspeed switch of the ESS.
Result
When (OPS1) or the WTS is tested at low engine idle, engine shutdown occurs.
(OPS1) or the WTS is faulty. Refer to Testing and Adjusting, "Engine Oil Pressure
Switch Test" and Testing and Adjusting, "Water Temperature Contactor Switch Test".
Replace a faulty switch. STOP.
When (OPS2) is tested at low engine idle, the engine continues to run. When the
engine accelerates, engine shutdown occurs.
Refer to Testing and Adjusting, "Engine Oil Pressure Switch Test" to test OPS2.
Replace a faulty switch. If no problems can be identified, the circuit breaker (CB7) may
have tripped. Check the wiring for a short circuit to the ground. STOP.
When OPS1 is tested at low engine idle, the engine does not stop. When the WTS
is tested, engine shutdown occurs.
The crank terminate switch of the ESS or the wiring to the ESS is faulty. Refer to
Testing and Adjusting, "Crank Terminate Speed Calibration". Diode (D4) may have
failed. Refer to Testing and Adjusting, "Diode Test". Replace the faulty component.
STOP.
When the WTS is tested, engine shutdown does not occur.
The jumper that is between terminals (TS-9) and (TS-10) of the junction box has not
been connected. Connect the jumper. If the jumper was not installed correctly, refer to
Testing and Adjusting, "Diode Test". Replace the diode (D3), if necessary.
When the OPS2 is tested with the engine at high idle, engine shutdown does not
occur.
The oil pressure step switch of the ESS, or the wiring to the ESS is faulty. Refer to
Testing and Adjusting, "Oil Step Speed Calibration". Ensure that the ESS has the oil
pressure step function. If terminals (ESS-13), (ESS-14), and (ESS-15) have wires that
are connected, the oil pressure step function is installed.
The Overspeed Verification Test does not cause engine shutdown by energizing
the fuel shutoff solenoid (FSOS). When the WTS is tested, engine shutdown
occurs.
The overspeed switch (OS) of the ESS may not be closing, or the wiring to the ESS may
be faulty. Refer to Testing and Adjusting, "Overspeed Calibration". The diode (D2)may
also be faulty. Refer to Testing and Adjusting, "Diode Test". Replace the diode, if
necessary. STOP.
The Overspeed Verification Test does not activate the air shutoff solenoid
(ASOS), if equipped.
The slave relay (SR2), the ASOS, or the air shutoff mechanism is faulty. Refer to
Testing and Adjusting, "Slave Relay Test". Repair the faulty components. STOP.
Copyright 1993 - 2016 Caterpillar Inc. Wed Jul 20 09:29:15 UTC+0700 2016
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Testing and Adjusting

Troubleshooting the ETR Full Protective System (OP, WT,

1. Check the engine fuel system.

a. Crank the engine.

The start/stop switch was not in the START position. Go to Step 2.

The problem is in the wiring to the 2301A Electric Governor. Go to Step 3.

2. Check the slave relay (SR1) and the fuel rack.

b. Measure the voltage at terminal (TS-11) of the junction box.

c. Reset the circuit breaker (CB7).

e. Remove the jumper when the test is completed.

The engine starts and the engine runs.

The engine does not start.

3. Check the slave relay (SR1).

c. Remove the jumper when the test is completed.

The engine starts and the engine runs.

The (SR1) is not faulty. Go to Step 4.

The engine does not start.

4. Check the protection components.

d. Remove the jumper when the test is completed.

The engine starts and the engine runs.

The engine does not start.

The problem is not in the protection components or in the ESS. Go to Step 8.

The problem has been solved. STOP.

6. Check the slave relay (SR2).

b. Crank the engine.

The engine starts and the engine runs.

7. Check the oil pressure step switch of the ESS.

b. Start the engine.

b. Crank the engine.

c. Remove the jumpers when the test is completed.

The engine starts and the engine runs.

The start/stop switch is in the STOP position.

Repair the faulty components.

The engine does not start.

The voltage is below 10 volts.

Go to the next result.

1. Check the start/stop switch.

c. Close the switch momentarily, but do not start the engine.

d. Disconnect the switch after the test is completed.

The engine cranks.

The engine does not crank.

b. Close the switch momentarily but do not start the engine.

c. Disconnect the switch after the test is completed.

The engine cranks.

The engine does not crank.

b. Close the switch momentarily, but do not start the engine.

c. Disconnect the switch after the test is completed.

The engine cranks.

The engine does not crank.

The ESS or the wiring to the ESS is faulty. Go to Step 5.

4. Check the components of the starting system.

a. Check the voltage at terminal (TS-24) of the junction box.

The voltage is low. Low voltage is between 1 volt and 20 volts.

The voltage is above 20 volts.

The voltage is zero (less than 1 volt).

5. Check the electronic speed switch.

b. Close the switch momentarily, but do not start the engine.