Electric Power

Olympian Product
David Noble
CPI Customer Service Manager
Larne, UK
 Contents
• Product support
• Service tools and Hardware
• Rebrand OLY to CAT
• Product health
• Q&A

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 Electric Power

Olympian Product Support

David Noble
CPI Customer Service Manager

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E Quest Updates
• E-quest replaces the present Olympian Technical Support email and phone based
system. All inquiries must be entered through the OLY E-quest website.

• Used to support Olympian Aftersales and Parts inquiries.

• Olympian Presales support and inquiries will continue to be supported through

CAT Application Support Centre.

• There is a lot of Presales information on the Knowledge base and frequently

asked questions tab, however they will not be able to raise a Presales inquiry and
will be directed to the CAT Application Support Centre.

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E Quest Updates – Equest link

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 Compass overview.- Compass online
• Serial number to Nov 2013 added.
• New models 1600 added.
• Two new recruits in the team
• Next update plan for Mid July – Back
to Monthly updates

New CD version available – Zip file has been SIFT

I can register this
for TC during the
conference

CD version you
can print parts
book.

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Perkins Engine Manuals
Zip file has been SIFT to Everyone at the TC conference

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 Power Net – Product Support

4
1 3

https://engines.cat.com/cda/alias/ep/products/olyint/ps

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 Power Net – Creation of CPI issue
• Include photos
• ECM downloads
• More information is
better

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 Reviewing Bulletins on Powernet
(1) Go to Internet site: https://engines.cat.com/ep/products/olyint/ps
(2) Select: Electric Power > Olympian Gensets international > Parts and Service

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Power Net – SB’s and TIB’s

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 EMC Notify - Trigger
https://emc.cat.com/

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EMC Notify - Trigger

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EMC Notify - Trigger

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 Power Net – e-GO
• e-GO enables the dealer to:
• View the price and availability of parts
• Place critical/emergency VOR orders
• Place Stock orders
• Track order progress

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 Power Net – e-GO

1
2

1a

2a

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Power Net - Contacts
https://engines.cat.com/ep/products/olyint/contacts

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Powernet: search product GA models / Wiring diagrams / Parts lists

• (1) Go to Powernet / Olympian gensets and

1 select Facility
3
3 • (2) Select genset model

• (3) Scroll down page and see GA models /

Wiring diagrams / Parts lists

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 CPI - Addition of OLY aftersales p/n’s to projects

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 CPI - Addition of OLY aftersales p/n’s to projects

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 Electric Power

Service Tool Software and

Hardware

David Noble
CPI Customer Service Manager

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Service Tool Software and Hardware
Electronic Governors
• Two different versions of Woodward Governors, the L-Series and the LCS.
• Individual service tool software and hardware requirements.
• Software License Key codes are available thru Olympian Service Parts.

Governor Type Device Service Part Comment

L-Series - Current Comm. Harness 917-508 or 261-5140
Comm. Kit 10000-00709 Includes RS-232<TTL
Converter
Converter 10000-16002 RS-232<TTL Only
Conversion Harness 10000-03526 or LCS to L-Series
279-5628
Software Free Download. http://www.woodward.c
No license required om/software/Download
LCS - Legacy Comm. Harness 997-169 or 928-264
Software Free Download. http://www.woodward.c
License required. om/software/Download

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Harson DCP10 and DCP20 Control Panels

• Low cost panel option on 400 / 1100 Packages

• Replacement files not set up on EPSS this should be requested through
Equest.

Software Required and Programming Instructions Can Be Downloaded From Power Net

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Hardware for communicating with DCP10 and DCP20

• DCP10 Communication lead • DCP20 Communication lead

required = 10000-55403 required = 10000-55404

DCP20

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Service Tool Software and Hardware
Power wizard you can use CAT ET and the Caterpillar communications
adapter 3

Download CAT ET
https://dealer.cat.com/cda/alias/CatET

Dealer Software licensing

https://dealersoftwarelicensing.cat.com/wba/login.do
• CAT ET
• Olympian EST
• Olympian Compass

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TIB0145 Converting PW 1.1 to PW 1.0

• Dealers are experiencing very long after sales lead times for old Power wizard 1.0 / 2.0 controllers. These controllers
are no longer used in production.

• PW 2.1 can be purchased and used to replace PW 1.0 or PW 2.0

• TIB0145 details how the PW 2.1 controller can be purchased and the current ECM replacement (Configuration file)
on EPSS can be converted to suit the new controllers

• In order to convert you will need access to the following systems:

1) EPSS: https://epss.cat.com/FGWEPSS/login.do
2) OLYMPIAN EST or CAT ET

• NOTE: This has to be OLYMPIAN EST or CAT ET version 2013A or greater in order to make this change

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EPSS Go to EPSS: https://epss.cat.com/FGWEPSS/login.do

1 2

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Service Tool Software and Hardware
Olympian Engines 1100 and 2000 you will require Olympian ET and the
Caterpillar communications adapter 3

Download Olympian EST

https://engines.cat.com/ep/products/olyint/ps/est

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Service Tool Software and Hardware
• Olympian Engines 1306 and 1606 you will require CAT ET installed
and the CA3.

• Need Adapter lead, CAT 7X-1686 OLY 10000-47892 to connect to

the service connector on the relay box.

• ECM needs power.

• Open DIAG1300/1600 to make sure to can Communicated. Software

- 10000-59498

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Service Tool Software and Hardware

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Service Tool Software and Hardware

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Service Tool Software and Hardware

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Service Tool Software and Hardware

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Service Tool Software and Hardware

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Service Tool Software and Hardware

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Factory Re rate

Perkins 1100, 1300, 1600 and 2000 you can

request factory password for CPI@CAT.com follow
instruction in LEXE0543.

1100 and 2000 will be factory passwords using

Olympian EST and Feature protection system.

1300, 1600 will be files supplied by the factory. To

create the flash file we require Package serial No.
Engine Serial No. and ECM serial No.

Also can request a new Olympian rating plate

using instruction on Product support news
LEXE0545

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Batteries & Charging Systems

Battery Types Battery Charging

• Low Antimony
– Lead antimony alloy
– Higher acceptance of Charge – Float Charge 13.5V
– Prone to overcharging – Boost Charge 14.1V
• Maintenance Free
– Lead calcium alloy
– Lower acceptance of charge – Float Charge 13.8V
– Tolerates overcharging – Boost Charge 15.6V
• Hybrid
– Lead antimony & Lead calcium alloys
– Mid ranged acceptance of Charge – Float Charge 13.5V
– Prone to overcharging – Boost Charge 14.7V

Batteries fitted to Generating Sets need to be ACCESSIBLE

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Batteries & Charging Systems

Battery Charging (1100 Series and below)

Designed to work with factory fitted batteries.

Fully programmable to work with any battery type

Requires software and connection kit - 10000 - 65102

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Delphi Fuel Pump Issues Troubleshooting

• TIB097 Use of Fuel conditioner for poor fuel

– Presentation of the positive affects of fuel conditioner.

• TIB0148 Misdiagnosis of L - series governor

• TIB0154 Upgrading to L - series governor for poor fuel quality.

• Weep hole leaks

• Warranty process and contacts

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Delphi Fuel Pump Issues Troubleshooting

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Why run with conditioner?

• Due to high failure rates on 3 cylinder injection pumps & various tear-downs in
the past it was deemed necessary to run a 1000 hours reliability test with the
addition of a fuel additive/conditioner.

• All returned pumps to date have had some fuel related failure, this varies from
sticking metering valves to worn internal governor components.

• The conditioning test was completed by Dealer in Saudi Arabia at two sites that I
previously visited. Both of these sites run continuous, supplying power to a
communication mast. Two original pumps & two pumps that ran with the fuel
conditioner have been returned to Delphi Warwick for teardown.

• Results are as follows.

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 Governor weights – Comparison

Without Conditioner

Notice wear marks

on heels & toes.
With Conditioner

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 Thrust Sleeve & Governor Arm - Comparison

Without Conditioner
Note: Thrust sleeve & governor arm wear With Conditioner

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 Thrust Washer – Comparison

With Conditioner Note wear on thrust washer face Without Conditioner

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Fuel Conditioner Summary

• As can be seen from the slides, the two pumps that ran with fuel conditioner have
no issues – these pumps could be re-built & return to service with the addition of
a gasket kit.

• Hours run on both pairs of pumps needs to be confirmed by FGW

• Fuel sample analysis has been completed on the conditioned fuel, the ‘Wear Scar’
test averages between the two sites as 310 microns.

• EN590 states that 460 microns is the maximum.

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Delphi Fuel Pump Issues Troubleshooting

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Delphi Fuel Pump Issues Troubleshooting

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Delphi Fuel Pump Issues Troubleshooting

Weep hole Back oil seal Front fuel seal

• Typical weep hole leaks are result of seal wear or fuel system restriction.
• If there is fuel leak the front fuel seal has failed due to restriction on return line
• Please return take pump to Delphi dealer for analysis.

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Delphi Pump Warranty process and contacts.
• https://engines.cat.com/ep/products/olyint/ps/warranty
• Go to: Delphi Fuel system Warranty process

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 Electric Power

Olympian to CAT Rebrand

David Noble
CPI Customer Service Manager

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 FGW OLY CAT

Std Option Std Option Std Option

Engine Perkins Perkins CAT

Non Leroy Leroy Leroy Leroy

Alternator Somer Somer Somer Somer

Skid Base Skid Base Skid Base

8Hr Narrow 8Hr Narrow 8Hr wide
Base Tankbase
Wide Tankbase
Tankbase
Wide Tankbase
Tankbase
Narrow Tankbase
DEFRA Tankbase DEFRA Tankbase DEFRA Tankbase

Control PW1.1/1.1+
PW1.1. 1.1+ EMCP4.2
DCP10 PW2.1 1002T PW2.1 EMCP4.1 4.3 / 4.4
Panel EGP2500

CAL CAL CAL

(Std Mild Steel
CAE CAE
Enclosure Opt Galv)
(both Galv) (both Galv)
CAE
(Std Galv)

Upfit Battery
Battery Battery
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Lift Arrangement Lift Arrangement
Ind Silencer
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Components Ind Silencer
Ind Silencer
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 Brand & Distribution

Current State Future State

Product Brand Distribution Product Brand Distribution

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 Pricelists & Nomenclature Change
Current New
400ROWT C2.2PGAT

GEP9.5-4 DE9.5E3

GEP13.5-6 DE13.5E3

GEP18-6 DE18E3

GEP22-6 DE22E3

1100ROWI / T C3.3PGAI / T
C4.4PGAI / T
C7.1PGAI / T
GEP33-3 DE33E0

GEP50-7 DE50E0

GEP55-3 DE55E0

GEP65-9 DE65E0

GEP88-3 DE88E0

GEP200-1 DE200E0

GEP220-1 DE220E0
553
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 Pricelists & Nomenclature Change
C2.2 = Engine

Current New
400ROWT C2.22PGAT

GEP9.5-4 DE9.5E3

GEP13.5-6 DE13.5E3

GEP18-6 DE18E3

GEP22-6 DE22E3

1100ROWI / T C3.3PGAI / T
C4.4PGAI / T
C7.1PGAI / T D = NA (60Hz)
GEP33-3 DE33E0 DE = ROW (50Hz or 60Hz)
GEP50-7 DE50E0

GEP55-3 DE55E0

GEP65-9 DE65E0

GEP88-3 DE88E0

GEP200-1 DE200E0

GEP220-1 DE220E0
554
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 Pricelists & Nomenclature Change
C2.2 = Engine

Current New PGA/B/C = Packaged Genset

400ROWT C2.22PGAT Revison A or B or C
GEP9.5-4 DE9.5E3

GEP13.5-6 DE13.5E3

GEP18-6 DE18E3

GEP22-6 DE22E3

1100ROWI / T C3.3PGAI / T
C4.4PGAI / T
C7.1PGAI / T D = NA (60Hz)
GEP33-3 DE33E0 DE = ROW (50Hz or 60Hz)
GEP50-7 DE50E0
33 = 33kVA
GEP55-3 DE55E0

GEP65-9 DE65E0

GEP88-3 DE88E0

GEP200-1 DE200E0

GEP220-1 DE220E0
555
5
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 Pricelists & Nomenclature Change
C2.2 = Engine

Current New PGA/B/C = Packaged Genset

400ROWT C2.22PGAT Revison A or B or C
GEP9.5-4 DE9.5E3
T/I/N/G/L = Build Facility
GEP13.5-6 DE13.5E3
T= Tianjin, I=Northern Ireland
GEP18-6 DE18E3
N=Newberry, G=Griffin, L=Lafayette
GEP22-6 DE22E3

1100ROWI / T C3.3PGAI / T
C4.4PGAI / T
C7.1PGAI / T D = NA (60Hz)
GEP33-3 DE33E0 DE = ROW (50Hz or 60Hz)
GEP50-7 DE50E0
33 = 33kVA
GEP55-3 DE55E0

GEP65-9 DE65E0
E0 = Non-compliant
GEP88-3 DE88E0

GEP200-1 DE200E0

GEP220-1 DE220E0
556
6
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 Product Support

DPC10
Support
 DSN
Control
Panels
DCP20  TMI
 SIS-Web
 Full Cat Manuals
 Morton Part Support
Present

1002  Standard Cat Warranty

PowerWizard 1.1
Re-Brand

PowerWizard 1.1+ EMCP 4.1

PowerWizard 2.1 EMCP 4.2

557
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 Electric Power

Olympian Product Health

David Noble
CPI Customer Service Manager

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 Part: 351-8754 & 351-8755 (PW1.1 Control panel) Failures = 185 CPI Project: 290110
CPI 290110 Open Active
Platforms affected: 400,1100,I6,4000.

Description: Powerwizard panel issues related to Hard Button Failures Resulting

Inability to Navigate and also gensets jumping out of auto mode.

Root Cause 1: facia was changed to a single layer for cost. Tracks printed on
only one side. i.e. Crossovers printed over existing tracks with a dielectric
between the two tracks. The dielectric breaks down causing trace shorting.

Root Cause 2:Software interrupt issue. When in Reduced Power Mode the
processor may reset kicking the control out of auto mode.

ICA 1: TIB152 allows use of control panel using spare digital inputs when buttons
fail.

ICA 2: TIB155 removal of reduced power mode.

PCA 1: Double Side Silver (DSS) Overlay In production for PW1.1 . Expected
production in march 2014 for rest of range through deviation.

PCA 2: Update software to eliminate reset when in reduced power mode. (Field
fix completed 23 Jan 2014)

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 Part: 335-2894 (Battery charger) Failures = 57 CPI Project: 257900

CPI 257900 Closed Resolved Dec 2012 Old Charger

Platforms affected: 400,1100.

Description: Lean 1100 product introduced new battery charger which has had failures in the field.

Root Cause 1: Battery charger locks out due to over current

Root Cause 2: Battery charger fails to charge due to capacitor solder joint failing.

ICA : TIB 100 details steps to reset the battery charger in situations where the charger has locked
out due current limit.

• In order to clear the fault condition, the AC and DC supply must be isolated and removed New Charger
from the charger for 10 seconds to allow the fault to be reset – the charger should then
operate normally.
• This can be verified by using a suitable ammeter to ensure current is being supplied by the
charger to the DC battery of the generator set.
• If the charger does not operate correctly, please replace with a new battery charger

PCA 1: New battery charger introduced by Computronic which removes the lock out feature on
over current. Introduced in December 2013

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 Part: 352-6019 (R450 AVR) Failures = 51 CPI Project: 258807

CPI 258807 Closed Resolved April 2012

Platforms affected: 400,1100,I6,4000

Description: No output of AC voltage due to AVR malfunction.

Root Cause 1: Solder bridge formed on some SMD on PCB, resulting in

the device (Capacitor) developing internal cracks.

Root Cause 2: Pin connector on Fast on plug not fully fitted into
housing.

ICA 1: Ensure that AVR is connected properly, firmly attach plugs. If the
AVR is still not operational please replace with same part.

PCA : PCB layout amended to allow for capacitors to be repositioned

and minimises the chance of a solder bridge forming. (Introduced Dec
2012)

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 Part: 269-2389 (Charging Alt) Failures = 35 CPI Project: 257114

CPI 257114 Closed Resolved Dec 2013

Platforms affected: 1300

Description: No output voltage from the charging alt

Root Cause 1: The root cause is due to the force from jet-washing. The
force from the water is cracking the bearing seals, leading to failure.

Root Cause 2: Electrical diode failures caused by isolation of the battery

during genset running. The output voltage from the charge alternator has
no where to go, which causes an instantaneous, very large voltage spike
within the charge alternator causing them to melt with the excessive
temperature increase.

PCA 1: Do not jet wash charging alternator. If damaged, replace with same
part.

PCA 2: Do not isolate the battery during genset operation. If damaged,

replace with the same part refer to TIB157.

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 Part: 10000-47899 (Stop solenolid) Failures = 21 CPI Project: 258586

CPI 258586 Closed Resolved May 2012

Platforms affected: 400.

Description: 400 series fuel stop solenoids are failing, the majority of reports
suggest either an internal failure or ´seized´/´sticking´ condition.

Root Cause 1: The supplier made a change to an assembly lubricant which was not
assessed on hot solenoids. Sticking occurs only in hot solenoids.

Root Cause 2: Solenoid cable breaks at the soldered joint to the connecting pin due
to a marginal design and application factors (strain on wire).

PCA 1: Change from soldered connection to riveted and spliced cable connection
to coil.

PCA 2: Fit ladder clip on GJ65691, GJ65692 and GJ65693 build list, to support
wiring to solenoid. This can be offered on other lists if required.

PCA 3: Assembly process at supplier modified to use an alternative assembly

lubricant

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 Part: 320-3064 (Oil pressure sender) Failures = 20 CPI Project: 267681

CPI 267681 Open Active

Platforms affected: 400,1100,I6,4000.

Description: Oil pressure values are not stable on PW1.1 When the engine is
stopped, it shows 60kPa. When the engine is running it has 240+60kPa
variations.

Root Cause 1: The range on Oil pressure sensor 10000-48495 (320-3064) is too
large for the application which gives unstable readings on the control panel.

Root Cause 2: Nuisance alarms with the PW control panels.

ICA 1: Change measurement units in Powerwizard from KPa to bar for

pressure will reduce variation of reading value.

ICA 2: Introduce a 5 second delay in warning event time and low shutdown
event delay as per TIB131.

Current status: New sender with reduced pressure range being tested by Cat
electronic, BB of project needs to arrange PMO plan to introduce this new
sender across the complete range of products. To be introduced in Q3 2014.

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 Part: 258-9755 (Engine Interface Modue) Failures = 19 CPI Project: 221481

CPI 221481 Closed Resolved Nov 2011

EIM Spade misalignment
Platforms affected: 400,1100,I6,4000.

Description: Engine Module (EIM) failures with majority stating the engine
will not start.

Root Cause 1: The pitch on the 4 way connector and the pins on the EIM
board are incorrect. This was as a result of a change to introduce lockable
connectors.

Root Cause 2: The design of the connectors on the EIM results in poor
PCA : replaced EIM with automotive relays
connection and inability to start the engine or even genset stopping when
the connector works itself loose due to vibration.

ICA 1: Check the spade connections are aligned on EIM PCB. Thoroughly
check that all connections in harness plug have fully engaged when fitted to
the EIM.

PCA 1: Correct the PCB layout so that the pitch of the pins match that of the
connector

PCA 2: Replaced the EIM with a series of auto motive relays externally
mounted on the engine.

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 Part: 312-0080 (R250 AVR) Failures = 19 CPI Project: 217697

CPI 217697 Closed Resolved April 2012

Platforms affected: 400,1100,I6,4000

Description: An issue has been identified on R250 AVR, CAT PN: 312-0080 x
ref FGW 10000-12943. Failure mode is unknown but particular failures have
occurred at 60HZ operation.

Root Cause : Bad soldering on the SMD diode D11 (Saw tooth generator).

PCA: The red glue used to seat SMD on the PCB is being replaced by a paste
solder process. (Effective from April 2012)

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 Part: Perkins 1306 engine Failures = 33 CPI Project: 259751

CPI 259751 Closed Resolved November 2012

Platforms affected: 1306.

Description: 1300 series engines suffering from high soot content in the oil, followed by
increased engine breathing and high oil consumption.
• This applies to the Perkins 1300 series engines with the EU stage 2 exhaust
emissions (year 2007 onwards) ECM flash file installed.
• Engines of the TAG4 and TAG6 ratings, and operating in prime power
applications, are most at risk.
• These symptoms are aggravated by high load factors and increased air inlet
restriction (blocked air cleaners).

Root Cause: EU stage 2 exhaust emissions ECM flash file caused incorrect fuel
metering at 1500rpm & 1800rpm, causing incomplete fuel combustion and severe soot
contamination of the engine oil.

ICA: TIB0127 should be applied as soon as possible. This explains how to re-flash the
engine ECM with the new “low soot” flash file, which can be supplied by the CPI team.

PCA: SB0099-PCA service bulletin can be applied where these engines have been
damaged by high soot content in the engine oil. The pistons, piston rings, cylinder
liners and fuel injectors should be replaced.
• Warranty is supplied based on the criteria detailed in SB0099-PCA.

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 Part: 10000-00082 (Fuel return hose) Failures = 581 CPI Project: 255065

CPI 255065 Closed Resolved July 2012

Platforms affected: 1103 & 1104.

Description: Fuel leaks from the small braided end of the return hose on
the engine. Also occurs on the return hoses between fuel injectors.

Root Cause 1: Incorrect glue application of the hose braid allowed

hardening, cracking & leaking. The material specification is correct.

ICA & PCA: Follow the instructions in TIB0114. New improved hose is
available which resolves this issue.
• Spares part number is 10000-00082.

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 Part: 954-048 (Coupling disc loose) Failures = 20 CPI Project: 314375

CPI 314375 Closed Resolved 25th Feb 2014

Platforms affected:1103 / 1104

Description: Issue reported on Leroy Sommer Generator

models LL2014C, LL2014H and LL2014J. Issue relates to the
inner coupling discs being potentially loose.

Root Cause: Operator did not follow the correct torque process
(twice in cross).

ICA: SB00109 released for field communication to fix after failure.

PCA: Additional torque process of re-torque 100% before

shipment.

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 Questions?

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