Engine Trouble Shooting

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Battery power too weak or batteries damage Charging or Replace

Wrong Connection or not properly Check and corrected
Genset cannot be turned Fuse burnt Replace
Failure shutdown nor Reset Trouble shooting and reset
DC breaker OFF position Turn on breaker
Improper starting procedure Review starting procedure
No fuel Check fuel tank
Air in Fuel line Bleed fuel line
Hard to start or will not start
Cold weather Use cold weather starting aids
Slow starter speed See "starter crank slowly"
Improper type fuel consult fuel supplier, use proper type of fuel
Water, dirt, or air in fuel system Drain, flush, fill and bleed system
Clogged fuel filter Replace filter element
Can be started but engine Dirty or faulty injection nozzles Have authorized dealer or engine distributer check injectors
knocks Injection pump shut-off not reset Turn key switch to "OFF" then to "ON"
Low engine oil level Add oil to engine crankcase
Injection pump out of time See your authorized servicing dealer of engine distibuter
Low coolant temperature Remove and check thermostat
Engine over heating See "Engine over heats"
Engine run irregularly or stall Clogged fuel filter Replace filter element
frequency
Water, dirt, or air in fuel system Drain, flush, fill and bleed system
Dirty or faulty injection nozzles Have authorized dealer or engine distributer check injectors
Below normal engine Defective thermostat Remove ansd check thermostat
temperature Defective temperature guage or sender Check gauge, sender, and connections
Engine over loaded Reduce load
Intake air restriction Service cleaner
Clogged fuel filter Replace filter element
Improper type of fuel Use proper fuel
Over-heated engine See "Engine over heats"
Below normal engine temperature Remove and check thermostat
Improper valve clearance See your authorized servicing dealer or engine distibuter
Lack of power
Dirty of faulty injection nozzles Have authorized dealer or engine distributer check injectors
Injection pump out of time See your authorized servicing dealer or engine distibuter
Turbocharger not functioning See your authorized servicing dealer or engine distibuter
Leaking exhaust manifolf gasket See your authorized servicing dealer or engine distibuter
Defective aneroid control line See your authorized servicing dealer or engine distibuter
Restricted fuel hose Clean or replace fuel hose
Low fast idle speed See your authorized servicing dealer of engine distibuter
Low oil level Add oil to engine crankcase
Low oil pressure
Improper type of fuel Drain, Fill crankcase with oil of proper viscosity and quality
Crankcase oil too light Use proper viscosity oil
Oil leaks Check for leaks in lines, gaskets and drain plug
High oil consumption
Restricted crankcase vent tube Clean vent tube
Defective turbocharger See your authorized servicing dealer or engine distibuter
Water in fuel system Drain and flush system
Low engine temperature Warm up engine to normal operating temperature
Engine out of time
Defective thermostat Remove and check thermostat
Defective injection nozzles See your authorized servicing dealer or engine distibuter
Engine out of time See your authorized servicing dealer or engine distibuter
Oil too light or bad quality Check replace it necessary
Engine emits gray exhaust Too much oil Drain to properly level
smoke
Combustion pressure low See your authorized servicing dealer or engine distibuter
Clogged or dirty air cleaner Service air cleaner
Engine emits black exhaust Engine over-load Reduce load
smoke Injection nozzles dirty See your authorized servicing dealer or engine distibuter
Turbocharger not functioning See your authorized servicing dealer or engine distibuter
Engine over-load Reduce load
Low coolant level Fill radiator to proper level, check radiator and hoses for loss connections
or leaks
Faulty radiator Have serviceman check
Loose or defective fan belts Adjust belt tension, replace as required
Engine over heats Low engine oil level Check oil level, add oil as required
Cooling system needs flushing Flush cooling system
Defective thermostat Remove and check thermostat
Defective temperature guage or sender Check water temperature with termometer and replace, if necessary
Incorrect grade of fuel Use correct grade of fuel

Improper type of fuel Use proper type of fuel
Clogged or dirty air cleaner Service air cleaner
Engine over-loaded Reduce load
Improper valve clearance See your authorized servicing dealer or engine distibuter
High fuel consumption
High fuel consumption
Injection nozzles dirty See your authorized servicing dealer or engine distibuter
Defective turbocharger See your authorized servicing dealer or engine distibuter
Low engine temperature Check thermostat
Oil too light or bad quality Check oil quality, replace if necessary
Low oil pressure Leaking Check hose, gaskets, connectors, turbocharger
Low oil level Add , check leakage
Excessive electrical load from added accessories Remove accessories or install higher output alternator
Excessive engine idling Increase engine RPM when heavy electrical load is used
Under-charged system Poor electrical connection on battery, ground, strap,

starter or alternator Inspect and clear as necessary
Defective battery Test battery

Defective alternator Test alternator
Cracked battery case Check for moisture and replace as necessary
Battery uses too much water Defective battery Test battery
Battery charging rate too high Test charging system
Loose or corroded connections Clean and tighten connections
Batteries will no charge Sulfated or worn-out batteries Check, replace as necessary
Loose or defective alternator belt Adjust belt tension or replace belts
PTO engaged Disengage PTO
Loose or corroded connections Clean and tighten loose connections
Starter does not work Low battery output voltage Check, replace if necessary
Faulty start circuit relay Check, replace if necessary
Blown fuse Replace fuse
Low oil pressure shutdown Check oil level(if low, check for leaks)
High temperature shutdown Check for cooling air restrictions or poor belt tension or overload
Low coolant level shutdown Chcek coolant level(if low, check for leaks)
Out of fuel Add fuel
Reset and start again, if fault again, contact an authorized service
Units stops suddenly Over-speed shutdown
distributer
Fuse blown in controller Replace fuse, if fuse burn again, contact an authorized service distributer
Over voltage shutdown Contact an authorized service distributer
Emergency stop switch activated(local or remote) See Resetting Emergency Stop Switches
MCCB tripped Check loads and close again

Safeguard breaker in OFF position Return to the ON position
No AC output
No AC output
Generator problem such as defective voltage regulator
Contact an authorized service distributer
or other internal fault
Unit over-load Reduce load
Low output or excessive drop Engine speed too low Contact an authorized service distributer
in volt
Faulty voltage rheostat or voltage regulator Contact an authorized service distributer
Oil grade not correct Replace with correct type(15W/40)
Oil temperature too low Turn on heater
Battery capacity too weak Replace
Genset not run or low speed Battery temperature too low Turn on heater if necessary
Battery terminals brunt, loose connection Chcek and reconnect
Charging not enough Check density of electolyte
Cranking parts or circuit problem Contact an authorized service distributer
Low speed,<rated speed Check and adjust
Starter engaged still Check and disengage the gear
Too cool, cold start aid required Check & replace or use col aid
Hard start or not Start Clogged fuel filter Replace
successfully(with exhaust
smoke) Air in fuel line Check and bleed fuel line
Fuel return hose blocked Check and clean
Intake line restricted Check intake system and restriction
Fuel too dirt or poor quality Replace or use a new fuel tank
No fuel in tank Add fuel
Fuel valve close Manual open, repair
Fuel not reach to injectors(air lock) Loosing connector during cranking
Engine cranking but not
successful(No exhaust smoke) Suction connector loosing Check and tightel all connectors
Clogged fuel filter or hose Check and replaced
No fuel in pump Full filling fuel in pump
Intake line or exhaust pipe restricted Check intake & exhaust system
Air in fuel system Check fuel line and connectors
Starter engaged still Check and disengage the gear
Genset can be started and run
but cannot run continuosly Too cool, clogged fuel filter Check & replace filter or use cold aid
Suction hose restricted Check & clean
Fuel too dirt or poor quality Replace or use a new fuel tank
PT pump main valve opened Check and turn to max position
Pump shutoff valve stuck Check all circuit
Cannot stop Vent hose blocked Check and clean
Fuel return hose blocked Check and clean
Combustible gas enter air intake system Clean and stop
Oil level not correct Check and add or drain some
Oil gauge defective Check and replace
Low oil pressure Oil was diluted Replace, if again contact with authorized dealer
Oil quality is not correct Check and replace
High oil temperature>120 ℃ Check the reason troubleshooting
Oil level not correct Check, should be > min. level mark
Filter blocked Check oil pressure, replace filter
Low oil pressure alarm Oil diluted or viscosity not correct Check reason & replace
Oil pressure circuit shorted Check circuit
High oil temperature>120 Check reason & troubleshooting
Low coolant level Add coolant
Radiator hose piping blocked Check & repair
Radiator inlet or outlet blocked Check, clean or replace
Cooling fan belt loosen Check tension and tighten
Oil level not correct Check, add or drain if necessary
High coolant temperature
Cooling fan impeller damaged Check impellers & replace
Check & replace if necessary
Expand tank damaged or installation not correct
Temperature gauge damaged Check and replace

Thermostat not open or cover on Check or replace, move radiator cover
Thermostat full open Check or replace
Low coolant temperature
Temperature gauge damaged Check, replace if necessary
Intake system blocked Check intake system
Turbo & cylinder head gasket leakage Check gaskets leaking
Black smoke with light load Fuel grade not correct Check fuel quality & replace
IN/OUT valve gaps or injector adjust not correct Check and adjust
Fuel return hose blocked Check return piping and connectors
Over loading Reduce load
Altitude too high Based on the data to derating
Fuel suction or filter blocked Check, clean or replace filters
High oil level Check and drain some oil
Intake throttle adjustment problem Check and adjust gently
Not enough power output
Intake or exhaust system blocked Check & clean
Air in fuel Check fuel system, fuel hose & tank
Fuel return line or vent hose blocked Check fuel line or replace
IN/OUT valve gaps or injector adjust not correct Check & adjust
Fuel bad quality Replace
Over load Reduce some loads
Tachometer defective Check & replace
Low speed after on load
Speed adjust level not correct Check & adjust
Fuel intake line blocked Check fuel line
Low coolant temperature Low coolant temperature troubleshooting
White smoke or Idle running
Poor fuel quality Check & replace

Engine Trouble Shooting

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Trouble Shooting

Uploaded by

Copyright:

Available Formats

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Battery power too weak or batteries damage Charging or Replace

Incorrect grade of fuel Use correct grade of fuel

Under-charged system Poor electrical connection on battery, ground, strap,

Defective battery Test battery

Over voltage shutdown Contact an authorized service distributer

MCCB tripped Check loads and close again

Temperature gauge damaged Check and replace

You might also like