December 20, 2024
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 |