Troubleshooting guide for generator

Brief introduction

The following problems listed below are provided the following:

  • Known problems
  • Possible causes of the known problems
  • Repair to correct the known problems

Fault diagnosis

 

generator
GENERATOR

1). When the starting switch is in the (ON) position, the engine crankshaft does not rotate.
Possible causes:
1. Low battery output voltage
Check the battery status and, if necessary, charge or replace the battery.
2. Wire or switch is damaged.
If necessary, repair or replace the parts.
3. Solenoid coil of the starter motor is damaged.
Install the new solenoid coil.
4. Starting motor is damaged.
Repair or replace the starting motor.

 

2). The engine can be not started (when the starting switch is in (ON) position, the engine crankshaft rotates)
Possible causes:

1. There is no the oil in the fuel tank
Fill the oil with the fuel tank
2. Poor fuel quality
Drain the fuel in the fuel tank, install new fuel filter element. Fill the high quality fuel with the fuel tank
3. Too dirty fuel filter
Install the new fuel filter
4. Ruptured or dirty fuel pipeline
If necessary, clean or replace the fuel pipeline
5. Too low fuel pressure
Replace the fuel filter, and check if the fuel delivery pump is working normally. If necessary, install a new fuel delivery pump.
6. There is the air in the fuel system
Locate the leaks in the fuel system, and repair the leaks. Remove the air in the fuel system
7. The fixed drain valve is turned on (insufficient fuel pressure, unable to start the engine)
Replace the fixed drain valve
8. Slow starting speed
Check the battery status, if necessary, replace the battery
9. The oil supply solenoid valve can be not opened
If the solenoid valve is damaged, replace or check the circuit system
When starting (such as starting the system at 12V), the start voltage shall be not less than 10V, 24V, and the system voltage shall be not less than 18V. Charge the accumulator or replace the accumulator.

3). The engine is not running smoothly
Possible causes:

1. Low fuel pressure
Ensure that the fuel tank is provided with the enough fuel. Check whether the fuel system is leaked. Check if the fuel pipeline between the fuel tank and fuel delivery pump is seriously bent. Check whether there is the air in the fuel system. Check the fuel pressure. Under full load speed, check if the fuel delivery pump is normal. Check the pressure difference between the front and back of fuel filter element. If the fuel pressure is reduced, install a new fuel filter element.
2. There is the air in the fuel system
Locate the leaks in the fuel system, and repair the leaks. Remove the air in the fuel system
3. The fuel pipeline between the fuel injection pump and fuel injection valve is leaked or broken.
Install the new fuel pipeline.
4. The valve clearance is incorrect.
Adjust the valve clearance. Refer to the Test and Adjustment Section.

4). Engine stalling at low speed
Possible causes:

1. Low fuel pressure
Ensure that the fuel tank is provided with the enough fuel. Check whether the fuel system is leaked. Check if the fuel pipeline between the fuel tank and fuel delivery pump is seriously bent. Check whether there is the air in the fuel system. Check the fuel pressure. Under full load speed, check if the fuel delivery pump is normal. Check the pressure difference between the front and back of fuel filter element. If the fuel pressure is reduced, install a new fuel filter element.
2. Low engine idle speed
Adjust the speed governor
3. The valve clearance is incorrect.
Adjust the valve clearance.

5). The engine speed is changed abruptly
Possible causes:

1. There is the air in the fuel system
Locate the leaks in the fuel system, and repair the leaks. Remove the air in the fuel system.
2. Governor tie rod is unable to move freely
Clean all the connecting rods. Clean the interior of the housing of the speed governor. Replace all damaged parts with new parts.

6). Underpowered engine
Possible causes:

1. Poor fuel quality
Drain the fuel in the fuel tank, install new fuel filter element. Fill the high quality fuel with the fuel tank
2. Low fuel pressure
Ensure that the fuel tank is provided with the enough fuel. Check whether the fuel system is leaked. Check if the fuel pipeline between the fuel tank and fuel delivery pump is seriously bent. Check whether there is the air in the fuel system. Check the fuel pressure. Under full load speed, check if the fuel delivery pump is normal. Check the pressure difference between the front and back of fuel filter element. If the fuel pressure is reduced, install a new fuel filter element.
3. There is the air in the fuel system
Locate the leaks in the fuel system, and repair the leaks. Remove the air in the fuel system
4. The air intake system is leaked
Check the intake pipe pressure. Check the air resistance of the air filter
5. The fuel is set incorrectly
If necessary, adjust the fuel adjustment and setting
6. Fuel adjustment tie rod
Adjust the tie rod to the full stroke. Replace the damaged or failed parts
7. The valve clearance is incorrect.
Adjust the valve clearance.
8. The filter screen of the filter of the fuel delivery pump is blocked
Remove and clean the filter screen

7). Severely vibrated engine
Possible causes:

1. The nuts used to fix the pulley are released
Tighten the nuts
2. Pulley is damaged
Install a new pulley
3. Engine base is loosened, worn or damaged
Tighten all mounting bolts. If necessary, install new components
4. Engine misfiring or engine is not running smoothly
Refer to the question 3
5. Fan blades are unbalanced
Loosen or remove the fan driving belts. Vibrations occur at the specific speed, start the engine at this speed in a short time. If the vibration does no occurs, replace the fan assembly

8). Large engine combustion noise (noise)
Possible causes:

1. Poor fuel quality
Drain the fuel in the fuel tank, install new fuel filter element. Fill the high quality fuel with the fuel tank

9). The noise appears in the engine valve bank (slight electrostatic interference sound)
Possible causes:

1. Broken valve spring or valve lock
If necessary, install new components. The valve lock is broken so that the valve may fall into the cylinder, thus damaging the cylinder.
2. Too large valve clearance.
Adjust the valve clearance. Refer to Test and Adjustment Section.
3. Inadequate lubrication
Check the lubrication of the valve chamber. At high speed of the engine, the engine oil flow should be very large; while the engine oil flow should be small at low speed of the engine. Oil passages must be clean, it is more important for oil passage that the engine oil is sent to the cylinder head.

10). There is the engine oil in the cooling system
Possible causes:

1. The movement of the oil cooler of the engine is damaged
Install a new movement in the oil cooler.
2. The water pore of the water pump is clogged or oil seal of the water pump is damaged.
Clean the blockage of the water pore of the water pump. Replace the oil seal

11). Mechanical noise in the engine (knocking sound)
Possible causes:

1. The connecting rod bearing is damaged
Check the bearing surfaces of the connecting rod bearing and crankshaft. If necessary, install new components.
2. Accessory failure
Repair the component or install new parts.

12). Excessive fuel consumption
Possible causes:

1. Fuel system is leaked
It is necessary to replace the parts at the oil leaked location.
2. Fuel and combustion noise (knocking sound)
Slight increase in fuel consumption may be caused due to the factors such as fuel spray nozzle fault, unsteadily engine running or other power loss, etc.
Refer to the questions 3 and 6.
3. Fuel is set too high
Adjusting the fuel setting.

13). Rocker arm is hardly moved, and the air valve clearance is too large
Possible causes:

1. Insufficient lubrication
Check the lubrication of the valve chamber. At high engine speed, the engine oil flow should be very large; while the engine oil flow should be small at low engine speed
2. Oil passages must be clean, it is more important for oil passage that the engine oil is sent to the cylinder head.
3. Valve clearance is too large
Adjust the valve clearance. Refer to Testing and Adjustment.
4. The bolts of the rocker arm bracket are loose.
Tighten the bolts to the torque of 15± 5N ? m (11 ± 4 lb ft)

14). The valve positioner or spring is broken
Possible causes:

1. The valve positioner is damaged
The valve lock is damaged so that the valve may fall into the cylinder, thus seriously damaging the cylinder.
2. The valve spring is damaged
Install the new valve spring

15). There is the engine oil in the exhaust gas
Possible causes:

1. Too much engine oil in the valve chamber
Ensure that the plugs are installed at the ends of the rocker arm shaft
2. The valve guide pipe is worn
It is necessary to repair the cylinder head.
3. The air filter element is clogged.
Replace the air filter element.

16). Valve clearance is too small or there is no valve clearance
Possible causes:

1. Valve seat or valve face is worn.
It is necessary to repair the cylinder head. Adjust the valve clearance. Refer to Testing and Adjustment,

17). Early abrasion of engine
Possible causes:

1. The dirt is contained in the lubricating oil
Drain the dirty lubricating oil. Install the new oil filter element.
Add the clean engine oil in the engine.
2. The air intake is leaked
Check all the gaskets, and repair the leaks found.
3. Fuel is leaked into the lubricating oil.

18). The coolant is contained in the lubricating oil
Possible causes:

1. The movement of the oil cooler of the engine is damaged.
Install the failed engine oil cooler with a new movement.
2. The water pore of the water pump is clogged or oil seal of the water pump is damaged.
Clean the blockage of the water pore of the water pump. Replace the oil seal

19). Excessive white smoke or blue smoke
Possible causes:

1. Excessive lubricating oil in the engine
Remove the excess engine oil. Identify its source. Add the appropriate amount of engine oil in the engine.
2. Engine misfiring or engine is not running smoothly
Refer to question 3.
3. The valve guide pipe is worn
It is necessary to repair the cylinder head.
4. The oil seal of the turbocharger is damaged.
Check whether there is the engine oil in the air inlet pipe. If necessary, repair the turbocharger.

 

20). Low engine oil pressure
Possible causes:

1. Oil pressure gauge is failed
Install the new oil pressure gauge
2. Dirty engine oil filter or oil cooler
Check the operation of the filter bypass valve. If necessary, install a new oil filter element. Clean the engine oil cooler movement or install a new movement. Empty the dirty engine oil in the engine, and fill the clean engine oil.
3. The diesel oil is contained in the lubricating oil
Locate the source that the diesel oil is filled into the lubricating oil. If necessary, repair. Empty the lubricating oil contaminated by the diesel oil. Install the new oil filter. Fill the clean engine oil in the engine.
4. The clearance between the rocker arm shaft and rocker arm is too large.
Check the lubrication of the valve chamber. If necessary, install new parts.
5. The suction tube of the oil pump is failed
It is necessary to replace the suction tube of the oil pump.
6. The pressure relief valve of the oil pump is running improperly
Clean the valve and housing. If necessary, install new parts
7. Oil pump is failed
If necessary, repair or replace the oil pump.

21). The engine is consumed too much lubricating oil
Possible causes:

1. The excessive lubricating oil is contained in the engine
Remove the excess engine oil. Identify its source. Fill the appropriate engine oil in the engine.
2. The engine oil is leaked
Find all the leaks. If necessary, repair.
3. High engine oil temperature
Check the operation of the oil cooler. If necessary, install new parts. Clean the oil cooler movement.
4. The excessive engine oil is added in the valve guide pipe.
Refer to Question 16.
5. The valve guide pipe is worn
Refer to Question 16.
6. The oil seal of the turbocharger is failed
Check the turbocharger. If necessary, repair the turbocharger

22). Overheating engine coolant
Possible causes:

1. The air flow or flow of the coolant via the radiator is limited
Remove all throttling parts.
2. Low coolant level
Add the coolant in the cooling system.
3. Pressure cap is failed
Check the operation of the pressure cap. If necessary, install a new pressure cap
4. The combustion gas is contained in the coolant
Identify the source that the combustion gas is leaked in the cooling system. If necessary, repair.
5. Temperature regulator or thermometer is failed
Check if the water temperature regulator or thermometer is operating correctly. If necessary, install new parts.
6. Water pump failure
Install a new water pump.
7. The system load is too large
Reduce the system load.
8. Loosened driving belt
Adjust the driving belt.
9. Antifreeze concentration is too high
50 percent antifreeze concentration is suitable under most situations.

23). The starting motor does not run
Possible causes:

1. Low battery output voltage.
Check the battery status. If necessary, recharge or replace the battery.
2. Wire or switch failure
Repair the wire or switch. If necessary, replace the wire or switch.
3. Starting motor solenoid coil is failed
Install a new starting motor solenoid coil.
4. Starting motor failure
Repair or replace the starting motor.

24). Alternator charge rate is low or irregular
Possible causes:

1. Alternator drive belt is loose
Adjust the drive belt to get the correct tension.
2. Charging, ground loop or battery connector failure
Check all cables and connectors. All connectors must be clean and tightened. Replace all faulted parts.
3. Alternator regulator failure
Repair or replace the alternator regulator
4. Alternator brush failure
Install the new brush
5. Rectifier diode failure
Replacing the faulted rectifier diode
6. Rotor (excitation coil) failure
Install the new rotor.

25). Alternator load is too large
Possible causes:

1.Alternator or regulator connector is loose.
Tighten all connectors of the alternator or regulator.
2. Alternator regulator failure
Install the new alternator regulator.

26). Alternator noise
Possible causes:

1. Alternator drive belt is worn or failed.
Install the new alternator drive belt.
2. Alternator drive belt pulley is loose
Check the key used to fix the pulley in the pulley groove. If the pulley groove is worn, install the new pulley. According to the requirements of the technical specifications, fasten the pulley.
3. The alternator drive belt is not aligned with the drive belt pulley.
Align the drive pulley with the drive belt pulley.
4. Armature rotor shaft is bent
Replace the rotor shaft.
5. Inadequate alternator rectification.
Replace the diode assembly.

27). Excessive exhaust gas temperature
Possible causes:

1. Air intake system or exhaust system damping
Remove the damping
2. Air intake system is leaked
Check the air intake system pressure, locate and repair the leaks.
3. The exhaust system is leaked
Locate and repair the leaks in the exhaust system.

Help us improve. Rate this post

Leave a Reply

Your email address will not be published. Required fields are marked *

2017 @ All rights reserved by Electricalmastar.com