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Comprehensive Guide to Diagnosing and Troubleshooting Diesel Generator Set Faults

December 20, 2024

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Generator Fault Diagnosis and Solutions

This Excel document offers a step-by-step approach to diagnosing and troubleshooting common issues with diesel generator sets. It highlights key fault symptoms and provides practical solutions to quickly resolve problems, ensuring efficient operation and minimizing downtime.

 

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Engine Fails to Start Air in the fuel pipe Remove air from the pipe
Speed signal interrupted Check the sensor and cable
Controller power disconnected or reversed Check the power supply and wiring
Governing mechanism transmission rod stuck at zero Reinstall and adjust
Controller output current limit value is too low Adjust the fuel supply potentiometer clockwise
External input protection is activated Check whether the system fault input terminal is always at a high level
Engine Overstarts Actuator and engine fuel mechanism misaligned Check and reinstall or adjust
Zero positions of actuator and mechanism mismatch Reinstall and adjust
Controller speed setting too high Reduce the set speed
Improper controller parameter adjustment Increase "GAIN" and "STAB" appropriately
Controller output current limit value too high Adjust the fuel supply potentiometer counterclockwise
Engine Speed Unstable Transmission rod between actuator and rack sticks or gaps Check and reinstall, and lubricate the actuator bearings with engine oil
Excessive engine load Reduce the engine load
Loose or worn speed sensor Tighten or replace the sensor
Incorrect speed sensor installation gap Check and reinstall (around 0.8 mm)
Improper controller parameter adjustment - If high-frequency vibration (>10 Hz), decrease "GAIN" and "STAB".
- If low-frequency oscillation (<1 Hz), increase "GAIN" and "STAB".
Engine Stops Automatically Controller power supply interrupted Check the power supply and cables
Speed feedback signal interrupted Check the sensor and cables
Speed setting signal interrupted Check the remote potentiometer and cables
Actuator cable open or short circuit Check the actuator and cables
Engine fuel supply interrupted Refuel and remove air from the fuel pipe
Overspeed protection activated with low frequency set Reset the overspeed protection frequency
Engine Fails to Stop Zero positions of actuator and fuel mechanism mismatch Check and reinstall or adjust
Fuel transmission mechanism stuck Check and reinstall or clean the mechanism
Controller power cannot be disconnected Check the power supply and connection cables
Engine Speed Cannot Be Adjusted Fuel transmission mechanism stuck Check, readjust, or clean the injection system
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