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5.
OPERATION
5.1 General
The generating set is equipped with an advanced
electronic control system. This will be one of a range of
systems such as a 1001, 2001, 4001, 4001E or
PowerWizard control system. See Section 4 of this
manual to identify which system is fitted on the generating
set and for a functional description of each.
These control systems allow the operator to manually or
automatically control the generating set. They have
protection circuits to sound an optional alarm and even
shutdown the set if problems occur. Details of the
capabilities of each system are contained in Section 4.
The following procedures detail the steps required to
prepare the set for operation and start and stop it normally.
A qualified generating set technician should start the set
for the first time after installation or after the set has been
out of service for a time for maintenance purposes. Section
5.2, Pre-Start Checks are applicable with all control
systems. Section 5.3 covers operation of the Keystart
Control Systems (1001 Series). Section 5.4, and 5.5 cover
operation of the Autostart Control Systems (2001, 4001
and 4001E Series). Section 5.6 and 5.7 covers operation
of the PowerWizard Series Autostart Control Systems.
5.2
Pre-Start Checks (applicable to all control systems)
The following checks should be performed prior to starting
the generating set:
WARNING:
!
As generating sets with autostart control panels
(2001 Series, PowerWizard or above) can be
remotely started without warning, always ensure
the control panel is switched off before carrying
out any checks.
1.
Ensure the Control Switch/Key Switch is Off on the
1001, 2001, 4001 and 4001E
OR
The Stop Key is activated on the PowerWizard panel.
WARNING:
!
Do not remove the radiator cap when the coolant
is hot. Do not add large amounts of cold coolant
to a hot system as serious damage could result.
2.
Check the engine oil and coolant levels - replenish as
necessary.
Note:
Diesel engines normally consume lube oil at a rate of
.25% to 1% of the fuel consumption.
When adding coolant to the radiator system, always
pour slowly to help prevent air from becoming trapped
in the engine.
WARNING:
!
When filling the fuel tank, do not smoke or use an
open flame in the vicinity.
3.
Check the fuel level - fill as necessary.
WARNING:
!
Before tightening the fan belts, disconnect the
battery negative (-) lead to ensure the engine
cannot be accidentally started.
4.
Check the condition and tension of the fan and
engine alternator belts - tighten as necessary.
5.
Check all hoses for loose connections or deterioration
- tighten or 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 for
heavy accumulation of dust and dirt - clean as
necessary. These can pose an electrical hazard or
give rise to cooling problems.
9.
Check the air filter restriction indicator, if fitted -
replace the filter as necessary.
10. Clear the area around the generating set of any
insecure items that could inhibit operation or cause
injury. Ensure cooling air ventilation screens are
clear.
11. Visually check the entire generating set for signs of
leaks from the fuel system, cooling system or
lubrication seals.
12. Periodically drain exhaust system condensate traps,
if equipped.
13. Ensure the Alternator Output Circuit Breaker is in the
"OFF" (handle down) position.
5.3
Normal Startup/Shutdown - Key Start Panel (1001
Series)
The following procedure should be used for normal starts
on a generating set equipped with a 1001 Series Key Start
Control System:
Note:
The generating set may be stopped at any time by
turning the Key Switch to Position "O" (Off).
1.
Complete Pre-Start checks as per Section 5.2.
2.
Check the battery voltage by turning the Key Switch
from Position "O" (Off) to Position "l" (On) and
reading the battery voltmeter. A fully charged battery
will indicate 12 to 14 volts on a 12 volt system or 24
to 28 volts on a 24 volt system. Return the Key
Switch to Position "O" (Off).
Note:
The engine will not start if any fault indicators are
illuminated. Reset the control system by turning the
Key Switch to Position "O" (Off). Ensure the faults
have been corrected prior to attempting to start the
generating set.
WARNING:
!
The Key Switch must not be turned to position
"
" or position "
running.
3.
Start: Turn the Key Switch from Position "O" (Off)
through Position "l" (On) to Position "
to activate the thermostart, if fitted. Hold for 7
seconds to preheat the induction air. After this time,
the Key Switch should be further turned to Position
"
" (Start) to crank the engine. When the engine
starts, release the Key Switch immediately allowing it
to return to Position "l" (On).
Do not crank the engine for more than 5 to 7 seconds
should the engine fail to start. Allow an interval of 10
seconds and always turn the Key Switch to Position
"O" (Off) between cranking attempts. If, after 4
cranking attempts, the engine still has not started,
refer to the trouble shooting guide in Section 4.5 or a
qualified generating set technician to determine the
cause of failure to start.
20
", while the engine is
" (Thermo)
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Table of Contents
Troubleshooting
