FAQ for diesel engine
1. Engine start failure
Reason:
A)Lack of battery charging
B)Control circuit poor contact/circuit break
C)Control module failure
D)Start relays failure
E)Start motor failure
F)Any malfunction of the start circuit
Approach:
A)Charging up accumulator, replace accumulator if necessary.
B)Exclude any disconnection/poor contact failure, check connector oxidation and change it if necessary. Clean oxide on the surface.
C)Replace the control module
D)Replace the starter relay
E)Contact with authorized personnel
F)Check all the other parts of the start circuit.
2. Engine start difficult or can not start, exhaust pipe smoke
Reason:
A)Start motor speed is too low
B)Fuel relay failure
C)Wrong use of the cold start device
D)Fuel filter blockage
E)Air exist in the fuel system
F)Suction fuel duct blockage
G)Air intake system blockage
H)Water in fuel
I)Use the wrong type or brand of the fuel
J)Injection pump inlet and return pipe connector is loose
K)Fuel pump failure
L)Fuel supply timing wrong
M)Valve timing wrong
N)Exhaust duct obstruction
Approach:
A)Refer to “can not start the engine” section.
B)Repair /replace the fuel relay.
C)View the user book to check how to operate the cold start system.
D)Replace the fuel filter
E)Vent the air from fuel filter
F)Clean the duct
G)Clean the intake system
H)Replace the fuel and install the oil-water separator.
I)Replace the fuel and try to start the engine
J)Tighten the pipe connector.
K)Check /repair fuel pump, if necessary, replace it.
L)Check fuel injection pump data and adjust.
M)Adjust to the required data
N)Inspect the exhaust pipe is blocked or not.
3. Engine start difficult or can not start, exhaust pipe no smoke.
Reason:
A)No oil in the fuel tank
B)Stop solenoid failure
C)Fuel delay failure
D)No oil spray from injector
E)Oil pump suction pipe joints loose
F)Fuel filter blocking or suction tube obstruction
G)Intake or exhaust system obstruction
H)Fuel pump failure
I)Injector hole obstruction
Approach:
A)Add fuel
B)Check electromagnet, replace it if necessary.
C)Repair /Replace the fuel relay.
D)Loose the injection pump hose, start the engine at the same time, check whether the fuel overflow
E)Tighten all of the filters pipe joints between the fuel tank and fuel pump.
F)Replace fuel filter, Check the fuel hose non-blocking
G)Check the intake and exhaust system has non-blocking
H)Check/repair fuel pump, replace it if necessary.
I)Check/ clean or replace the fuel injector
4. Engine can start but can not keep running
Reason:
A)Air exist in the fuel system
B)Fuel relay failure
C)Fuel system leak or blockage
D)Fuel filter blockage
E)Using the wrong type or grade of fuel
F)Water in fuel
G)Intake system blocking
Approach:
A)Vent the air out from the fuel system
B)Repair/replace the fuel relay
C)Check the fuel line
D)Replace fuel filter
E)Replace the fuel
F)Replace the fuel and install the oil-water separator
G)Clean intake line
5. Black smoke
Reason:
A)intake /exhaust system blocking
B)injector fault
C)cold start system failure
D)using wrong type or brand of fuel
E)exhaust duct obstruction
F)wrong valve clearance
G)return pipe blocking
Approach:
A)Check intake /exhaust system have a non-blocking
B)Check/adjust or replace injector
C)Check the start system
D)Replace the fuel
E)Check the exhaust pipe is blocked or not, check the pipe size is correct or not.
F)Adjust the valve clearance
G)Check the return line non-blocking
6. Take the blue smoke or white smoke
Reason:
A)Using the wrong type of lubricant
B)Cold start system malfunction
C)Excessive engine lubrication oil
D)Turbocharger seals and bearing wear
E)Using the wrong type or grade of fuel
F)Go over the engine overhaul deadline
G)Water leak of the cylinder head
Approach:
A)Replace the lubrication oil and filters and make sure to choose the correct type of oil.
B)Install the cold start device, inspect, repair or replace it if necessary.
C)Check the oil level
D)Repair /replace turbocharger
E)Replace fuel
F)Engine overhaul
G)Inspect cylinder head and gasket, replace it if necessary.
7. Engine can not reach to rated speed
Reason:
A)Overloaded too much
B)Tachometer mistake
C)Suction tube obstruction
D)Government failure or improper settings
E)Government mix speed is set too low
F)Water in fuel
Approach:
lReduce the load
lCheck the speed by handheld or digital tachometer
lCheck the inlet non-blocking, replace it if necessary.
lCheck/adjust the governor
lCheck/adjust the governor
lReplace the fuel, install oil-water separator
8. Engine can not be shut down
Reason:
H)Poor contact / open circuit
I)Controller stop button failure
J)Stop solenoid failure
K)Fuel return pipe blocking
Approach:
1.Exclude any disconnection /poor contact failure, inspect the connector for oxidation, and clean it if necessary.
2.Replace/repair controller stop button
3.Check /replace the stop solenoid
4.Check the return pipe non-blocking, distorting or depression.
9. Engine output power shortage
Reason:
nOverload too much
nDecline of power caused by high altitude
nHigh ambient temperature
nFuel duct obstruction
nIntake or exhaust system blocking
nAir exist in fuel – air bubbles in fuel system
nReturn pipe blocked or the fuel tank with poor ventilation
nUsing the wrong type or grade of fuel
nInjection pump failure
Approach:
A)Reduce the load
B)Correct the power output when the altitude is more than 1000meters.
C)Correct the power output when the temperature is over 40Centigrade
D)Inspect the fuel system non-blocking
E)Inspect the air intake and exhaust system have a non-blocking
F)Vent the air from fuel, tighten the pipe connector and filter.
G)Check the fuel return system had non-blocking
H)Replace the fuel
I)Check /replace the fuel injection pump
10. Low oil pressure
Reason:
1.lubricants bit inappropriate
2.oil pressure meter /sensor failure
3.wrong oil grade
4.oil filter blocking
Approach:
J)Check for lubricant leaks. Add or emission lubricants.
K)Check the oil pressure meter /sensor
L)Replace oil, choose the correct grade
M)Replace the oil filter
11. High water temperature
Reason:
O)Coolant level is too low
P)The radiator is blocked or damaged
Q)Radiator hose depression or obstruction
R)Fan drive belt slack
S)Lubricants bit inappropriate
T)Thermometer failure
U)Water temperature sensor failure
V)Fan damaged
W)Water pipe obstruction
X)Water pump failure
Y)Thermostat failure
Approach:
A) Add coolant
B) Clean the radiator according to the instruction, repair it if necessary.
C) Check the hose, replace if necessary.
D) Check the tension of the belt, tight if necessary.
E) Add or emission lubricants. Check the oil dipstick scale.
F) Inspect/repair the water temperature meter. Replace if necessary.
G) Check /repair the water temperature sensor
H) Replace the fan
I) Check and clean the water pipes
J) Check/repair the water pump
K) Check/repair the thermostat
12. Engine running is unstable
Reason:
nFuel pipe obstruction
nFuel pump failure
nFuel filter is dirty
nGovernor is set incorrectly
nInjector failure
nFuel tank ventilation blocked
nAir exist in fuel system
nAir filter blocked
nValve clearance is incorrect
nLubricants excessive, or use the wrong grade/brand of oil.
Approach:
a)Check /replace the fuel pipe
b)Check/repair fuel pump, replace if necessary
c)Replace the fuel filter
d)Adjust /replace governor
e)Check /adjust or replace injector
f)Clean-up / install the ventilation tube
g)Vent the air from fuel
h)Clean /replace air filter
i)Inspect /adjust valve clearance
j)Check /adjust the amount of oil or replace it.
13. Engine vibration
Reason:
nInjector fault
nThe governor is set incorrectly
nEngine assembly fault
nInjection pump failure
nFlywheel housing, flywheel concentricity doesn’t meet the requirements
Approach:
A)Check /repair injector
B)Adjust / replace governor
C)Contact with authorized personnel
D)Contact with agency to repair the pump
E)Contact with agency
FAQ for alternator
1. No voltage output when running
A. Check the connection of AVR F1-F2 is correct and reliable.
B. Check the outlet is correct
C. Check the remanence voltage, magnetized if necessary
D. Check the fuse in control box is normal
2. Output voltage is instable
A. Check the speed of the unit is stable.
B. Check the settings of AVR is correct
3. Output voltage is too high
A. Check whether the engine speed is too high or not.
B. Check/ adjust the settings of AVR
4. No-load voltage is too low
A. Check the engine speed is too low
B. Check the settings of AVR
5. Load voltage is too low
A. Check the engine speed
B. Check whether it is overloaded or not.
C. Check/ adjust the settings of AVR
FAQ for electric control system
1. Generator sets don’t start when press down the start button.
A. Check whether any loose happened in the circuit or not, whether the controller is good or not.
B. Check any malfunction indication, repair the faults and reset the corresponding fault information.
C. Check that the emergency stop button is relaxed.
D. Check the battery voltage. If the voltage is too low, recharge the battery to full. If the voltage is normal, please check whether the voltage signal is sent to every control units step by step according to the circuit diagram, such as the throttle solenoid valve and starting motor etc…
2. Generator sets can not start even the start motor is workable
A. Check the fuel level and ensure that the tubing is properly connected
B. Check the fuel relay abnormal
C. Check the fuel delivery system if there is air and clogged
D. Check the air filter is blocked or not
E. In cold regions, ensure the machine is preheated before starting.
3. High water temperature fault alarm/shutdown
A. Check whether it is overloaded
B. Check the radiator is blocked
C. Check the fan belt tightness
D. Check the coolant level after the machine is completely cooled down.
E. Check whether the water temperature sensor is damaged or not
F. Check whether the thermostat valve is correctly opened
G. Check whether the gap between the pump and radiator is correct.
H. Confirm the temperature of the generator room is not higher than 40centigrade
4. Low oil pressure alarm / shutdown
A. Check the oil level
B. Check the oil pressure sensor is damaged
C. Check the oil filter and duct is not blocked
D. Check the oil quality and viscosity
E. Check the oil temperature
5. Over speed shutdown
A. Check the setting of the overspeed protection in the controller, adjust if impropriety
B. For mechanical type governor, inspect the throttle lever is flexible and ensure proper regulation.
C. For electrical type governor, check the settings of the governor and adjust if necessary.
D. reset the alarm signal on the screen after troubleshooting.
6. High voltage alarm
A. Check the high voltage protection limit setting in the controller, adjust if impropriety.
B. Measure the actual value of the output voltage
C. Confirm that the display instrument is no deviation
D. If the actual voltage is too high, check and adjust the AVR following the steps.
E. Confirm the speed /frequency is normal
F. If the actual voltage is normal, check the voltage display circuit.
7. Low voltage alarm
A. Check the low voltage protection limit setting in the controller, adjust if impropriety.
B. Measure the actual value of the output voltage
C. Confirm that the display instrument is no deviation
D. If the actual voltage is too low, check and adjust the AVR following the steps.
E. Confirm the speed /frequency is normal
F. If the actual voltage is normal, check the voltage display circuit.
G. Confirm the load changes slightly when an alarm occurs
H. Ensure that the generator sets is not overload working
8. In automatic mode, the generator sets can not start up automatically
A. Check the connection between generator sets and ATS is correct
B. Confirm the ATS converter switch is not in “AUTO” position
C. Confirm the ATS control wire is not loose
D. Check whether the fuel relay is normal, replace if necessary
