dingbo@dieselgeneratortech.com
+86 134 8102 4441
dingbo@dieselgeneratortech.com
+86 134 8102 4441
Sep. 26, 2021
This part describes and lists some common faults in the use of generator set, possible causes of the fault and methods to determine the fault. The general operator can determine the fault and repair it according to the instructions. However, for operations with special instructions or unlisted faults, please contact the maintenance agent for maintenance.
The following recommendations must be kept in mind before carrying out maintenance:
Be sure to study the fault carefully before any operation.
First use the easiest and most common maintenance methods.
Be sure to find the root cause of the fault and completely solve the fault.
1. Diesel generator set
This part of the description is for reference only. If such failure occurs, please contact the service dealer for repair. (some models of control panels are only equipped with some of the following alarm indicators)
| Indicator | Reasons | Faults analysis |
| Low oil pressure alarm | If the engine oil pressure decreases abnormally, this light will be on. | Lack of oil or failure of lubrication system (fill oil or replace filter).This fault will cause the generator set to stop automatically immediately. |
| High water temperature alarm | When the engine coolant temperature rises abnormally, this lamp is on. | Water shortage or oil shortage or overload.This fault will cause the generator set to stop automatically immediately. |
| Low diesel level alarm | When the engine coolant temperature rises abnormally, this lamp is on. | Lack of diesel or stuck sensor.This fault will cause the generator set to stop automatically immediately. |
| Abnormal battery charging alarm | This light is on when the diesel oil in the diesel oil tank is below the lower limit. | Battery charging system failure.This fault will cause the generator set to stop automatically immediately. |
| Start failure alarm | If the charging system fails and the engine is running, this light will be on. | Fuel supply system or starting system failure.This fault will not stop the generator set automatically. |
| Overload, or circuit breaker trip alarm | This light is on when the generator set fails to start for 3 (or 6) consecutive times. | In case of this fault, remove part of the load or eliminate the short circuit, and then close the circuit breaker again. |
2.Diesel engine
Engine StartFailure | Faults | Reasons | Solutions |
| Start motor failure | Battery voltage too low;The main circuit breaker is in the off position;Broken / disconnected electrical wiring;Start contact / start button failure;Faulty start relay;Faulty starting motor;Engine combustion chamber water inlet. | Charge or replace the battery;Close the main circuit breaker;Repair damaged or loose wiring. Check that there is no oxidation at the connection;If necessary, clean and prevent embroidery;Replace the start contact / start button;Replace the start relay;Contact maintenance engineer. | |
| Start motor speed is low | Battery voltage is low;Broken / disconnected electrical wiring;Air in fuel system;Lack of fuel;Diesel valve half closed;Lack of oil in tank;Diesel filter blockage; | Contact maintenance engineer. Do not attempt to start the engine;Charge or replace the battery;Repair damaged or loose wiring. Check that there is no oxidation at the connection;If necessary, clean and prevent embroidery;Bleed the fuel system;Open the diesel valve;Fill up with diesel;Replace the diesel filter with a new one. | |
| The starting motor speed is normal, but the engine does not start | Oil stop solenoid valve connection failure;Insufficient preheating;Wrong starting procedure;Pre heater inoperative;Engine intake blocked. | Check whether the oil stop solenoid valve acts;Check whether the circuit breaker of the pre heater trips and recloses the circuit breaker; Start the generator set according to the procedures required in the instructions;Check whether the wire connection and relay are normal. If there is any fault, please contact the maintenance engineer. | |
| The engine stops after starting or the operation is unstable | Air in fuel system;Lack of fuel;Diesel valve closed;Diesel filter blocked (dirty or dirty);Diesel waxing at low temperature);Oil stop solenoid valve connection failure;Insufficient preheating;Wrong starting procedure;Pre heater inoperative;Engine intake blocked;Injector failure. | Check the air inlet system of the room and the air filter of the generator set;Bleed the fuel system;Fill up with diesel;Open the diesel valve;Replace the diesel filter with a new one;Check whether the oil stop solenoid valve acts;Check whether the pre heater circuit breaker trips and recloses the circuit breaker;Start the generator set according to the procedures required in the instructions;Check whether the wire connection and relay are normal. If there is any fault, please contact the maintenance engineer. | |
| Too high cooling water temperature | Water shortage in engine or air in cooling system;Thermostat fault;Radiator or intercooler blocked;Cooling water pump failure;Temperature sensor failure;Incorrect injection timing. | Check the air inlet system of the room and the air filter of the generator set;Check and replace the fuel injection nozzle; Fill the engine with coolant and bleed the system;Install a new thermostat;Clean the radiator of the unit regularly according to the maintenance table;Contact the authorized maintenance engineer. | |
| Too low cooling water temperature | Thermostat fault | Check and replace the temperature sensor;Install a new thermostat. | |
| Unstable engine running speed | Engine overload;Insufficient fuel supply;Diesel filter blocked (dirty or dirty);Diesel waxing at low temperature);Water in fuel;Insufficient engine air intake;Air filter blocked;Air leakage between turbocharger and intake pipe;Turbocharger fault;Insufficient air circulation in the machine room;Air inlet volume control failure of air inlet duct;Back pressure of smoke exhaust system is too high;Incorrect adjustment of fuel injection pump; | Reduce the load if possible;Check the oil supply system;Replace the diesel filter with a new one;Replace diesel;Check the air filter or turbocharger;Replace the air filter with a new one;Check the pipeline and connection. Tighten clip;Contact the authorized maintenance engineer;Check that the vent pipe is not blocked;Adjust the air inlet volume control of the air inlet duct;Check any possible sharp corners of the smoke extraction system;Contact the authorized maintenance engineer;Contact the authorized maintenance engineer; | |
| The engine cannot be stopped | Exhaust purifier failure;Electrical connection failure (loose connection or oxidation);Stop button failure;Shutdown solenoid valve / oil shutdown solenoid valve failure; | Repair connections that may be broken or loose. Check the connection for oxidation, and clean or waterproof if necessary;Replace the stop button;Contact the authorized maintenance engineer. | |
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