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4.6 

Control System Fault Finding/Trouble Shooting Guide 1001, 
2001, 4001, 4001E 

 

 

FAULT SYMPTOM 

REMEDY 

Engine Fails to Start  
(1001 Series Only) 
 

Engine Does Not Crank 
when Key Switch Turned to 
Position "

" (Start) 

 

1.  Check operation of Key Switch. 
2.  Check no fault lamps illuminated.  Reset, if required, after remedying indicated 
fault. 
3.  Refer to a qualified generating set technician. 

Engine Fails to Start  
(2001, 4001, or 
4001E Series Only) 

Engine Does Not Crank 
when Start Signal Given, 
Either Manually Via Control 
Switch or Automatic-ally Via 
a Remote Signal 

1.  Check all Emergency Stop Pushbuttons are released (including any remote 
buttons).  If no remote stop is used, have the technician ensure "Remote Stop" 
terminals are linked. 
2.  Check that Control Switch is not off. 
3.  Check no fault lamps illuminated.  Reset, if required, after remedying indicated 
fault. 
4. Refer to a qualified generating set technician.  

Engine Fails To 
Start  
(All control systems) 

Engine Cranks But Does Not 
Fire Or Engine Starts But 
Stops After 20 Seconds. 
(“FAIL TO START” Fault 
Lamp Illuminates on 2001, 
4001 or 4001E Panels.) 

1.  Check fuel level. 
2.  Check that  Canopy External Emergency Stop Pushbuttons, if fitted, are not 
depressed (1001 Series). 
3. Refer  to a qualified generating set technician. 

Engine Stops Due 
to Low Oil Pressure 
(All control systems)  

“LOW OIL PRESSURE” 
Fault Lamp Illuminates 

1.  Refer  to a qualified generating set technician. 

Engine Stops Due 
to Overspeed  
(2001, 4001 or 
4001E Series Only) 

“OVERSPEED” Fault Lamp 
Illuminates 

Note: The “OVERSPEED” fault lamp will also illuminate after the Emergency Stop 
Pushbutton has been depressed even though there has been no overspeed 
condition.  The Emergency Stop Pushbutton and any remote stop buttons must be 
released before the fault can be cleared. 
1. Refer to a qualified generating set technician. 

Engine Stops Due 
to High Lube Oil 
Temp 
(Optional 
Shutdown) 

“HIGH LUBE OIL TEMP” 
Fault Lamp Illuminates 

1. Refer to a qualified generating set technician. 

Engine Stops Due 
to Low Coolant 
Level 
(Optional Shutdown 
- 2001, 4001, 4001E 
Series Only) 

“LOW COOLANT LEVEL” 
Fault Lamp Illuminates 

1. Refer to a qualified generating set technician. 

Engine Stops Due 
to Low Fuel Level 
(Optional Shutdown 
- 2001, 4001, 4001E 
Series Only) 

“LOW FUEL LEVEL” Fault 
Lamp Illuminates 

1. Check fuel level in day tank.  Fill as necessary. 
2. Refer to a qualified generating set technician. 

Engine Stops Due 
to Overvoltage 
(Optional Shutdown 
- 2001, 4001, 4001E 
Series Only) 

“OVERVOLTAGE” Fault 
Lamp Illuminates 

1. Refer to a qualified generating set technician. 
 

Engine Stops Due 
to Under-voltage 
(Optional Shutdown 
- 2001, 4001, 4001E 
Series Only) 

“UNDERVOLTAGE” Fault 
Lamp Illuminates 

1. Refer to a qualified generating set technician. 
 

Engine Stops Due 
to Overvoltage 
/Under-voltage 
(Optional Shutdown 
- 2001, 4001, 4001E 
Series Only) 

“OVERVOLTAGE/UNDER-
VOLTAGE” Fault Lamp 
Illuminates 

1. Refer to a qualified generating set technician. 
 

Engine Stops Due 
to Earth Fault 
(Optional Shutdown 
- 2001, 4001, 4001E 
Series Only) 

“EARTH FAULT” Fault Lamp 
Illuminates 

1. Refer to a qualified generating set technician. 

Engine Stops Due 
to Earth Leakage 
(Optional Shutdown 
- 2001, 4001, 4001E 
Series Only) 
 

“EARTH LEAKAGE” Fault 
Lamp Illuminates 

1. Refer to a qualified generating set technician. 

 

 

11

Содержание OLYMPIAN 1001 Series

Страница 1: ...GENERATING SET OPERATOR S MANUAL ...

Страница 2: ...i ...

Страница 3: ... otherwise operating the generating set The Generating Set Technical Operation and Maintenance Manual the Engine Manual and the Alternator Manuals are designed for qualified generating set technicians for installation maintenance and trouble shooting of the set Document PWPO1 GB Issue Date 02 09 Part Number 277 584 ii ...

Страница 4: ...rol System Fault Finding Trouble Shooting Guide 1001 2001 4001 4001E 11 4 7 Control System Fault Finding Trouble Shooting Guide PowerWizard Panels 13 4 8 Load Transfer Panels 19 4 9 Engine Interface Module Description 19 4 10 Output Circuit Breaker Description 19 5 OPERATION 20 5 1 General 20 5 2 Pre Start Checks applicable to all control systems 20 5 3 Normal Startup Shutdown Key Start Panel 1001...

Страница 5: ...ting set room is properly ventilated Keep the room the floor and the generating set clean When spills of fuel oil battery electrolyte or coolant occur they should be cleaned up immediately Never store flammable liquids near the engine Store oily rags in covered metal containers Do not smoke or allow sparks flames or other sources of ignition around fuel or batteries Fuel vapours are explosive Hydr...

Страница 6: ...e chest to rise Let the chest fall completely Give breaths at a rate of 10 per minute 4 If the victim must be left to get help give 10 breaths first and then return quickly and continue 5 Check for pulse after every 10 breaths 6 When breathing restarts place the victim into the recovery position described later in this section IF NO BREATHING AND NO PULSE 1 Call or telephone for medical help 2 Giv...

Страница 7: ...trical power is produced by an alternator fine tuned to the output of this generating set The engine and alternator are coupled together and mounted on a heavy duty steel baseframe Except for the largest sets this baseframe includes a fuel tank with a capacity of approximately 8 hours operation at full load An extended capacity fuel tank of approximately 24 hours operation may be fitted instead Th...

Страница 8: ...ing set is running ensure that the AC voltmeter selector switch is not in the OFF position 2 AC VOLTMETER SELECTOR SWITCH A selector switch allowing the operator to select voltage reading between phases or between a phase and neutral The OFF position allows the voltmeter zero position to be checked while the generating set is running 3 AC AMMETER An ammeter that indicates the AC electrical current...

Страница 9: ...ents the red light will turn off 6 ALARM ACKNOWLEDGMENT SILENCE Pressing the Acknowledge key will cause the horn relay output to turn off and silence the horn Pressing the key will also cause any yellow or red flashing lights to turn off or to become solid depending on the active status of the alarms The Acknowledge key may also be configured to send out a Global Alarm Silence on J1939 Data Link w...

Страница 10: ...p position When shutting down the generating set the load should be turned off by switching the alternator output circuit breaker to OFF handle down The engine should be allowed to cool prior to stopping it After a few minutes the Key Switch is turned to Position O Off which shuts the generating set down In case of emergency where immediate shutdown is necessary the Key Switch should be turned to ...

Страница 11: ...7 14 EMERGENCY STOP 1001 Series Panel 2001 Series Panel 4001 Series Panel 4001E Series Panel PowerWizard Series Panel Figure 4 1 Diagram of Typical Control Panels ...

Страница 12: ...een reset When low oil pressure is sensed the generating set is automatically shut down The RED SHUTDOWN LIGHT will begin to flash until the ACKNOWLEGE key is pressed The RED SHUTDOWN LIGHT will stay on until the fault has been resolved on the generating set the LOW OIL PRESSURE shutdown event has been reset Engine speed is monitored by the speed sensor in the fly wheel housing of the generating s...

Страница 13: ... system is reset 4 5 7 Automatic Preheat Control glow plugs operates automatically prior to and during engine cranking The automatic cranking sequence will be delayed by the preheating period 4 5 8 Remote Annunciator Panels 8 or 16 channel remote annunciators may be fitted and connected to 4001 and 4001E Series Control Systems These provide repeat indicators for the shutdown and alarm fault lamps ...

Страница 14: ...out in two triangular formations These give indication of which phase voltage or current is being measured In the case of the voltmeter one LED illuminated indicates the phase to neutral voltage for that particular phase If two LED s are illuminated then the voltage shown is the phase to phase voltage for these two phases Only one LED will be illuminated below the ammeter This LED shows which phas...

Страница 15: ...EED fault lamp will also illuminate after the Emergency Stop Pushbutton has been depressed even though there has been no overspeed condition The Emergency Stop Pushbutton and any remote stop buttons must be released before the fault can be cleared 1 Refer to a qualified generating set technician Engine Stops Due to High Lube Oil Temp Optional Shutdown HIGH LUBE OIL TEMP Fault Lamp Illuminates 1 Re...

Страница 16: ...2 Refer to a qualified generating set technician Alarm for Low Coolant Temp Optional Alarm 2001 4001 4001E Series Only LOW COOLANT TEMP Alarm Lamp Illuminates 1 Check that the immersion heaters are switched on and are operating 2 Refer to a qualified generating set technician Generating Set Does Not Go On Load All control systems Generating Set is Running but the Load is Not Being Powered 1 Check ...

Страница 17: ...ssed or the Stop key is held down for 5 seconds and Cooldown time is skipped 2 Refer to a qualified generating set technician Engine Stops Due to Low Oil Pressure Low Oil Pressure in event log Red Shutdown LED Illuminates 1 Refer to a qualified generating set technician Engine Stops Due to High Coolant Temp High coolant temp in event log Red Shutdown LED Illuminates 1 Refer to a qualified generati...

Страница 18: ...sed 3 Check Circuit Breaker is on handle up 4 Refer to a qualified generating set technician Alarm for Approaching High Engine Temp APPROACHING HIGH COOLANT TEMP Alarm in event Log Amber LED Illuminates 1 Refer to a qualified generating set technician Alarm for approaching low oil pressure APPROACHING LOW OIL PRESSURE Alarm in event Log Amber LED Illuminates 1 Refer to a qualified generating set t...

Страница 19: ...nce in circuit 114 Engine coolant temperature signal out of range low Defaults to 180 F 82 C Signal voltage less than 0 127V Short circuit to earth 115 Engine coolant temperature signal out of range high Defaults to 180 F 82 C Signal voltage greater than 4 6V Open circuit Sensor failure 121 Manifold air pressure signal out of range high Defaults to ECM setting Low power Slow acceleration Signal vo...

Страница 20: ...test in engine off test only Open circuit or short circuit to earth 244 Engine data link failed open circuit test Output circuit test in engine off test only Open circuit or short circuit to earth 254 Open circuit test out of range high High voltage during open circuit test 255 Open circuit test out of range low Low voltage during open circuit test 311 Engine oil temperature signal out of range lo...

Страница 21: ... high to low 451 Number 1 injector unit short circuit to B or earth high Found by the ECM Injector unit electrical wiring loom shorted to earth low 452 Number 2 injector unit short circuit to B or earth high Found by the ECM Injector unit electrical wiring loom shorted to earth low 453 Number 3 injector unit short circuit to B or earth high Found by the ECM Injector unit electrical wiring loom sho...

Страница 22: ...ting code and ECM do not match ECM programming fault Components not compatible 621 Engine using default rating Engine operates AL25 HP default ECM installed but not programmed 622 Engine using field default rating Engine limited to 160 HP Options not available ECM installed but not programmed 623 Invalid engine rating code ECM not programmed correctly 624 Field default active Programming problem E...

Страница 23: ...he mains the Mains Available indicator will illuminate but the generator will continue to supply load When it is convenient for retransfer to take place the operator presses the Retransfer Button which causes the load to be transferred back to the mains and after a cool down period automatically shuts down the generator 4 8 2 TC Compact Load Transfer Panel The TC Compact Load Transfer Panel is des...

Страница 24: ... replace as necessary 6 Check the battery terminals for corrosion clean as necessary WARNING When working with the batteries do not smoke or use an open flame in the vicinity Hydrogen gas from batteries is explosive Do not short the positive and negative terminals together 7 Check the battery electrolyte level fill with distilled water as necessary 8 Check the control panel and the generating set ...

Страница 25: ...e engine fires The engine will automatically crank up to 3 times or until the engine fires If the engine does not fire the control system locks out on FAIL TO START and illuminates a fault lamp on the control panel If this happens refer to the trouble shooting guide in Section 4 5 or a qualified generating set technician to determine the cause of failure to start WHEN ENGINE HAS STARTED 3 Check fo...

Страница 26: ...y abnormally high temperature or abnormally low oil pressure Pressing the ENGINE OVERVIEW key will display these readings The oil pressure should be in the normal range within 10 seconds of starting 6 Switch the Alternator Output Circuit Breaker to ON handle up 7 Shutdown To shut the generating set down turn off the load by switching the alternator Output Circuit Breaker to OFF handle down Press t...

Страница 27: ...spheric pollution Dealing with lead acid batteries can be hazardous so it is important to follow all safety guidelines Battery acid can burn clothing and skin and even cause blindness if it leaks so wear protective clothing when inspecting a battery prior to its disconnection transportation Disconnect the battery safely before inspecting it see below Before removing a battery carry out a thorough ...

Страница 28: ...24 HAZARD LABEL LEGEND Some or all of these hazard warning labels will appear on your generating set ...

Страница 29: ...werWizard 8 Functional Description PowerWizard Control Systems 8 Gauges 9 Heaters 8 Hours Run Meter 4 Key Switch 4 Load Transfer Panels 19 Maintenance 22 Meters 9 Normal Manual Startup Shutdown 22 Oil Pressure Gauge 4 Overspeed Signal EIM Plus only 19 Panel Equipment 4 5 PowerWizard 5 PowerWizard Autostart Panels 22 Pre Start Checks 20 Rating Label 3 Remote Annunciator Panels 9 Safety 1 Chemical 1...

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