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Engine part
1: if there is air in the fuel system, first check whether the fuel pipe joints are loose; and then remove the air in the fuel pump. First unfasten the vent screw on the fuel injection pump and fuel filter; pump the fuel with the hand pump, until there is no air bubbles in the overflowing fuel pump; Then tighten the vent screw, continue pumping; when fuel flows into the return pipe, then tighten the hand pump.
2: If the fuel pipe is clogged, pls check and ensure that the fuel pipes are not clogged.
3: If the fuel filter is clogged, pls clean the filter or replace the filter element.
4: If the fuel pump doesn’t work or fails while working, pls check the fuel transfer pump and the fuel intake pipe.
5: If there is insufficient fuel injection, failed injection or fuel not atomized, pls replace injector assembly.
6: if the injection pump speed governing lever placed in a wrong position, when starting the engine, place the lever in such a position that the engine rotates at 600-800 r/min at no-load.
7: if it is misconnection or loose of electric wires, pls check that the electric wires are firmly and reliably connected.
8: If it is insufficient battery capacity, pls replace with a well-charged battery or use batteries in parallel.
9: If the electronic speed governor failed, please follow the testing procedures specified in the handbook for the electronic speed governor (actuator, control panel, speed sensor) and find out the reason.
10: If the fuel injection advance angle is too earlier or too late, or even 180° apart. Engine can not ignited or extinguished after brief ignition, Pls check whether the scribed lines on the splicing tray of the fuel pump drive shaft are correct and secured. Adjust if necessary.
1: Fuel system fault: cannot increase rev and output power, even when the throttle is increased.
★ If the fuel pipe or filter is intruded by air or gets clogged, pls vent the air or replace fuel filter insert as aforementioned.
★ Fuel supplied by the pump does not get atomized, Pls repair or replace assembly.
★ Inadequate atomization of the injector or injecting pressure too low, pls check atomizing or adjust injection pressure. Pls check whether the injector assembly shall be replaced.
2. Air intake and exhaust systems fault: the exhaust smoke has a higher temperature and worse color than normal.
★ If the air filter is clogged, pls wash the air filter element or wipe off the dust on it. Replace it if necessary. Pls also check that the engine oil level is normal.
★ If the exhaust pipes clogged or pipe joints too long, or elbows having a small bend radius or more elbows than necessary, pls clean off the carbon deposits in the exhaust pipe, reinstalling the pipe, reduce the number of elbows, enlarge elbow bend radius.
3. Engine block overheating; ambient temperature too high; oil and coolant temperature too high; exhaust temperature too high, Pls check the cooler and radiator, clear off furring; Check relevant piping to ensure there is no pipe that is too slim. If the ambient temperature is too high, improve room ventilation to cool it down.
1.If the drive gear wearing, enlarged clearance: abnormal sounds from the front cover; collision noises heard when the engine suddenly slows down. Pls adjust gear clearance; replace the gear if it is worn out.
2.No oil between the rocker adjusting screw and the pushrod spheric seat: squeaks of dry friction heard from the cylinder head. Remove the cylinder head case and add oil.
3.Enlarged intake and release valve clearance: rhythmic noises from the cylinder head.
Pls adjust gear clearance; Adjust valve clearance.
1. Black smoke:
★ If the engine overloaded, pls reduce the load to rated level.
★ If uneven fuel supply among the cylinders, pls adjust fuel injection pump.
★ Inappropriate valve clearance and/or bad seal results in gas leakage and incomplete combustion, pls adjust valve clearance; check the conical seal surface and remove any defect.
2. White smoke:
★ if it is inadequate atomization of the fuel, fuel liquid drops, injection pressure too low.
Pls check the injector assembly; reprocess or replace it; adjust the injection pressure to rated level.
★ Incomplete combustion in individual cylinder (esp. in winter) when the engine is just started, pls increase engine speed and load by an appropriate extend and let the engine run for a prolonged period.
★ Air filter clogged, obstructing air intake. Check and clean air filter element.
★ Piston ring choked or excessive wear; reduced flexibility; piston ring chamfer installed in wrong location, causing oil intrusion into the combustion chamber, Check piston ring and replace it if necessary.
★ Engine constantly runs at low load (below 40% of rated output): enlarged clearance between piston and cylinder jacket, causing oil intrusion into the combustion chamber, Pls increase the load appropriately.
★ Excessive amount of oil in the oil pan, Reduce the amount of oil until the oil level drops down to rated level. Fill oil according to the markings on the dipstick.
★ Oil pipe leakage, Check and repair, tighten screw nuts.
★ Air intrusion into the oil pump; lack of oil in the oil pan, Replace the oil after topping up the oil to rated level.
★ Serious oil leakage in such locations as the crankshaft thrust bearing, oil seal of the flanged end of the crankshaft, camshaft bearing and connection rod axial bush, check all the parts and replace any if it is worn out.
★ Rupture of the connecting oil pipe between rocker shafts; no oil injector is installed to lubricate the drive bearing or the oil injector is displaced from its fixed position. Check, repair or replace.
★ oil cooler or oil filter clogged; rupture of cooler pipe; leakage on the seal gasket or gasket damaged, Clean, weld or replace the filter element. If aluminum bits are found in centrifugal oil filter, it means that the alloy layer on the connecting rod axial bush is ripped off. Check for the bush and replace it if necessary; check and replace seal gasket.
★ Oil pressure gauge damaged, Replace it.
★ Oil passage clogged, Clean after check and repair
★ Oil pump severely damaged or choked because of unskilled installation, Check and repair; adjust the clearance; test the pump for performance.
★ Oil pressure control valve fails, the spring damaged, Replace the spring; rub the seal surface of the control valve.
The reading on the oil temperature gauge is beyond rated value; it doesn’t drop much even after enhanced cooling. Black smoke is seen from the exhaust.
★ Diesel engine overloaded
Reduce load
★ Oil cooler or radiator clogged
Wash cooler or radiator piping
★ Inadequate coolant or wind flow from the fan
Ensure that the coolant flows unobstructed; adjust the tension of the V belt to let the water pump and fan reach rated speed.
★ Inadequate oil
Fill the oil to rated level.
★The temperature gauge doesn’t work rightly
Check and adjust or replace
Solution: Oil level in the oil pan drops quickly; the color of the oil is dark; white smoke is seen from the oil refilling hole on the vent pipe and blue smoke is seen from the exhaust pipe:
★ Oil of inappropriate grade is used
Chose the right grade of oil as specified by the Generator produce.
★ Piston ring gets stuck or worn out; cylinder jacket gets worn out so that oil intrudes into the combustion chamber, combusting gas intrudes into the crankshaft case.
Replace piston ring; replace cylinder jacket if necessary.
★ Oil return hole of the piston oil control ring gets clogged with carbon deposits
Clear off the carbon deposits.
★ The elastic sealing of the turbocharger (if equipped)fails to function, Check the elastic air sealing for ability to continue function; replace if necessary
★ Engine operates at low load for long time.
Increase the load appropriately.
The coolant infiltrates into the engine oil; yellow bubble floats on the oil; water vapor condenses on the surface of the vent pipe filter element:
★ Cylinder jacket water tight gasket damaged, resulting in water leakage
Replace the water tight gasket.
★ Cylinder head gasket damaged, resulting in water leakage.
Use new gasket.
★ For wet oil cooler, the cooler element damaged, resulting in the mixture of cooling water and oil.
Check the cooler element, repair or replace.
★ Cooling water infiltrates from the fresh water pump into the oil pan Leakage of water on the fresh water pump shaft and seal gasket
Check the water tight ring, repair or replace; rub the sealing surface
There is air in the water pipe: little or no water flows through the outlet pipe, resulting in rising water temperature.
Unfasten the water temperature gauge joint on the water pipe, vent the air until water flows unobstructed. Then tighten all joints on the water piping.
★ There isn’t enough water being circulated. At high loads, the outlet water would become very hot and engine oil would also be too hot.
• Fresh water pump or cooling fan doesn’t rotate fast enough
Adjust the tension of the V belt until it meets requirement.
• The rotor blades of the fresh water pump gets damaged
Replace.
• The clearance is too wide between the rotor blade and the pump case(壳体).
Adjust the clearance until it meets requirement
• In open circulation system, the water supply end is so low that the water pump is unable to suck up the water.
Lift the water supply end.
• In closed circulation system, the radiator lacks water.
Add cooling water
• Water pipes get clogged.
Clean the pipes, clear off fouling, Clean the surface of the radiator.
★ In closed circulation system, the radiator surface is covered with dirt, affecting the heat emission. Replace.
★ Thermostat doesn’t work.
Repair or replace.
★ Water temperature gauge doesn’t work.
Replace the cylinder jacket.
★ In open circulation system, the raw water intrudes into the engine.
Install a water mix tank.
★ Thermostat doesn’t work well or gets damaged.
Replace.
★ Ambient temperature is low or the load is low.
Increase the load properly.
★Water temperature gauge does not show correct data.
Check or replace.
★ Starter motor doesn’t work.
1. poor contact at electric connections.
Clean and tighten electric connections.
2. poor contact at brushes.
Clean the commutator or replace the brush Eliminate short circuit.
3. starter motor short circuit.
Repair.
4. Inadequate charging of the battery or battery capacity too small.
Charge the battery or use more batteries in parallel; replace battery if necessary.
5. poor contact on electromagnetic switch contact points
Check the contact points and abrade them with sand paper.
★ Starter motor gear gets choked with the flywheel ring gear or starter motor gear can’t be disengaged:
1. starter motor not in parallel to the center of the flywheel ring gear
Reinstall the starter motor and parallel it to the flywheel ring gear center.
2. sintered electromagnetic switch contacts
Check the contacts; file, abrade and singe them.
★ Starter motor continues running after start button is released:
1. the moving contacts of the electromagnetic switch sintered with the connection screw
Check and repair.
2. starter motor governing screw not adjusted properly.
Readjust the screw.
★ Abnormal noises with the alternator.
1. Loose or broken bearings.
Replace the bearings.
2. collision between rotor and stator.
Rub off the collision surface with a file.
★ Battery refuses charging; or unable to provide strong current while voltage drops sharply; white lead sulfate crystals appear on the plates:
Repair or replace the battery.
★ When charging, the battery temperature is high; the voltage is low; the electrolyte proportion is low; bubbles are too small towards the end of charging or come out too late; short circuit inside the battery.
If inside short circuit is caused by excessive deposits at the bottom of the battery, discharge the battery completely, pour out the electrolyte, rinse the battery several times and recharge it. If inside short circuit is caused by other reasons, dismantle the battery and have the separators/plates repaired or replaced.
Alternator
Connect Terminal “E+” and “E-” to a 4-12V new battery, and maintain it for 2-3 seconds. (Pay attention to polarities).
★ When the battery is removed, voltage reaches the rated level. Magnet field loss.
★ When the battery is removed, voltage is established but doesn’t reach rated level.
1. Check AVR reference signal connection
2. Diode fault
3. Exciting armature short circuit
★ When the battery is removed, no voltage is established.
1. AVR fault
2. exciter field winding wiring open circuit (check the winding)
3. main rotor winding wiring open circuit (check the resistance)
Check the rev, when the rev is correct, pls check the following:
★ Check AVR wiring (AVR might have failed)
★ Field winding wiring short circuit
★ rotating diode damaged
★ main rotor winding wiring open circuit (check the resistance)
When the rev is too low, pls check the following:
Increase the rev(do not adjust the AVR voltage-potentiometer before the rev reaches rated level).
Adjust AVR voltage-potentiometer, if Adjustment fails, it means the AVR failure.
Voltage
Adjust AVR steady-state potentiometer), If the adjustment fails, try normal/fast mode (ST2)
★ Check the rev: possibility of nonperiodical oscillation
★ Loose connection
★ AVR failure
★ Engine rev is too low at loads or LAN configuration too high
Let the alternator run at no load, check the voltage between “E+” and “E-” on AVR.
1. The direct current voltage between “E+” and “E-” SHUNT/PMG < 10V, Check the rev (or LAN configuration too high)
2. The direct current voltage between “E+” and “E-” SHUNT/PMG >15V.
★ Rotating diode failure.
★ Main rotor short circuit, check resistance.
★ Exciter armature failure, check resistance.
Check AVR, varistor, and rotating diode; replace any failing components,
Voltage does not return to rated level,
★ Exciter field winding wiring open circuit
★ Exciter rotor failure
★ AVR failure
★ Main rotor open circuit or short circuit.
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