Annual generator problem...any ideas?

[chaffcutter]

We bought a CAT Olympian generator back in 2014 to run our grain dryer (not enough total power on our supply). This is wired into the mains which keep it charged and warm at all times ready to start.

BUT it doesnt! every time we want to start it, several fault codes come up and it won't go. Ring service, they come out but not before taking a cash payment of about £900 on the credit card, "we will refund if its less to fix" yeah like hell more like a further bill.

last repair was in 2017 as of course it wasn't used last year. "Oh the warranty on that has expired now..."

getting to the wit's end now, what next?

Trading Standards have referred me to Citizens Advice but they've gone home now, anyone had good results through them?

 

[Chae1]

@leone75

 

[leone75]

We bought a CAT Olympian generator back in 2014 to run our grain dryer (not enough total power on our supply). This is wired into the mains which keep it charged and warm at all times ready to start.

BUT it doesnt! every time we want to start it, several fault codes come up and it won't go. Ring service, they come out but not before taking a cash payment of about £900 on the credit card, "we will refund if its less to fix" yeah like hell more like a further bill.

last repair was in 2017 as of course it wasn't used last year. "Oh the warranty on that has expired now..."

getting to the wit's end now, what next?

Trading Standards have referred me to Citizens Advice but they've gone home now, anyone had good results through them?

Send me the codes and the serial no and I'll have a think

 

[chaffcutter]

OK will be tomorrow now, thanks

 

[Pheasant Surprise]

We bought a CAT Olympian generator back in 2014 to run our grain dryer (not enough total power on our supply). This is wired into the mains which keep it charged and warm at all times ready to start.

BUT it doesnt! every time we want to start it, several fault codes come up and it won't go. Ring service, they come out but not before taking a cash payment of about £900 on the credit card, "we will refund if its less to fix" yeah like hell more like a further bill.

last repair was in 2017 as of course it wasn't used last year. "Oh the warranty on that has expired now..."

getting to the wit's end now, what next?

Trading Standards have referred me to Citizens Advice but they've gone home now, anyone had good results through them?

They don’t like to be kept standing for long periods without a start really.

Best to try and run it at least once a month with some decent load on the engine and electrical load on the set itself for around 30 minutes. Don’t run them unloaded.

This keeps the main alternator windings moisture free and keeps the engine (hopefully) sweet.

 

[Clive]

Send me the codes and the serial no and I'll have a think

It’s the control panel that keeps failing - basically 1 per year every year at over 1k to replace each year we have used it


It’s a 200kva Olympian- was not cheap ! We thought we were paying a premium for a premium product that would last many years

Has done less than 250hrs total and just 12.3hrs on this current panel

Current fault says - high fuel level (it’s not)so I suspect yet again a new control panel will be required

The engine and generator itself is fine and as good as new but the control panels are clearly just not fit for the purpose it seems

Cat (Finnings Uk) Attitude and service stinks - just happy to take £1k plus of us every year when we want to start using it again and service manager refuses to put us in touch with anyone higher up the management chain

 

[Kevtherev]

I’ve sent a PM clive/chaffcutter
Midland electrical services
(Dave parry)

 

[Clive]

They don’t like to be kept standing for long periods without a start really.

Best to try and run it at least once a month with some decent load on the engine and electrical load on the set itself for around 30 minutes. Don’t run them unloaded.

This keeps the main alternator windings moisture free and keeps the engine (hopefully) sweet.

It’s constantly mains connected to circulate warm coolant and we do run it out of season periodically

No issues with the engine / Jenny or any of it than might not like being stood (odd for a “backup generator”). It’s the control panels that seemingly have a built in self destruct system set on a 12 month timer

 

[Clive]

I’ve sent a PM clive/chaffcutter
Midland electrical services
(Dave parry)

If we can’t get Cat to do anything we will have to remove their electronics and replace with someone else’s I guess - pointless buying yet another cat control box just for it to fail again next year

 

[bobk]

If we can’t get Cat to do anything we will have to remove their electronics and replace with someone else’s I guess - pointless buying yet another cat control box just for it to fail again next year

Bypass the control panel and run it manually , why can't you get enough leccy .

 

[Clive]

Bypass the control panel and run it manually , why can't you get enough leccy .

Not sure running a big engine with no overheat or low oil pressure, power surge etc protection is a good idea ! This was a very expensive bit of kit, we shouldn’t be having to bodge it ! Not sure you even could without a complete rewrire either

We have 250kva 3 phase mains to our yard but a lot going on (some high consumption tenants share our yard) at peak times it’s not enough to run the dryer and connected cleaner / conveyor systems, upgrade of mains would cost 5 figures plus due to distance, the generator solves that (when it works !)

 

[bobk]

Not sure running a big engine with no overheat or low oil pressure, power surge etc protection is a good idea ! This was a very expensive bit of kit, we shouldn’t be having to bodge it ! Not sure you even could without a complete rewrire either

We have 250kva 3 phase mains to our yard but a lot going on (some high consumption remnants share our yard) at peak times it’s not enough to run the dryer and connected cleaner / conveyor systems, upgrade of mains would cost 5 figures plus due to distance, the generator solves that (when it works !)

You need a substation , 100k should sort it .

 

[Pheasant Surprise]

It’s the control panels that seemingly have a built in self destruct system set on a 12 month timer

What make of control panel is it?

If it's not a common rail engine (even if it is) then it's actually not terribly difficult to swap out the control panel.

 

[Simmy]

Give Burns generators a ring. 07769170440. Mick runs a lot of cat generators. Hires them out all over. He might be able to point you in the right direction or fix it himself.

 

[Simmy]

Forgot to say... if he doesn't answer keep trying every half hour.

 

[TripleSix]

Fit a Deep Sea electronics panel, I've not had any reliability issues with them

 

[chaffcutter]

Last time it was done they spoke about a Deep Sea but wanted£££££s to get it fitted

 

[Exfarmer]

Have you spoken to FW Murphy?
They are the big names in engine controllers
They used to make computerised controllers which I am sure would be suitable

 

[Mursal]

Would it be dampness, condensation, moisture causing the panel to fail?
Usually control panels are reliable, unless stressed one way or another.

 

[Vincent]

There are hundreds of those sets out there on stand by with out any fault. Post a few pics of the panel and the faults.