Chapter 1 Malfunction and Troubleshooting for Diesel Engine
1. Causes and Troubleshooting for the Engine Not Being Started
CAUSES
It is cold
Machine oil is viscous
Failure of fuel system
Water mixed in the fuel
The fuel get thickening and can’t flow
easily
Air exists in fuel system
Injection fuel is little or the spray is not
excellent
Incomplete combustion
Interrupted of diesel fuel
Deficiency in pressure of compression;
Loosen in the nut of cylinder head;
Damage or leakage in the gasket of cylinder
Big gap in the piston ring due to wear and
tear
Leakage caused by each gap of piston ring
lined in one direction
Serious stickiness or breakage in piston
ring
Leakage in gas valves
Incorrect in valve clearance
The valve stem is clipped in the guide pipe
TROUBLESHOOTING
Fill machine oil into crankcase after warming-up.
Fill machine oil into inlet pipe
Remove the connection belt from the machine
Start the engine and stop it when it is heating, assemble the belt
and then restart the engine.
Clean fuel tank, fuel filter and fuel pipe, then change the fuel.
Use prescribed brand fuel
Emit the air, tighten each connect part to the fuel pipe
Check the position of governing handle or check and clean the
fuel nozzle, change the nozzle if necessary.
Mainly by ill spray
Incorrect delivery angle
Leakage in gasket of cylinder head
Deficiency in pressure of compression
Lack of oil, should fill fuel into the fuel tank. If have obstruction
or leakage in the fuel pipe and fuel filter, drain out them with the
air.
Tighten the nut of cylinder head in the diagonal sequence; check
the gasket of cylinder as per the standard requirement. When the
engine with the new gasket is heating, tighten the nut of cylinder
head again.
Change the piston ring
Make each gap of piston at angle of 120
Clean it by diesel fuel or change the piston ring.
Skive the gas valve, or send it to repair factory if the vestige is
too deep.
Adjust the gap as specified.
Disassemble the gas valve, clean the stem and guide pipe with
diesel fuel.
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2 Causes and Troubleshooting for Deficient Power of Diesel Engine
CAUSES
Malfunction of fuel system;
Parts obstruction in fuel filter and fuel pipe;
Inadequate fuel supplying;
Bad pressing of fuel pump
Malfunction of the fuel nozzle;
Incorrect injection pressure
Carbon deposit in the nozzle hole
Needle was bit
Loose fit between needle and needle body
Obstruction in air filter
Not fast enough of engine speed
3 Causes and Troubleshooting for Engine Stopping Automatically
CAUSES
Malfunction of the fuel system
Run out of fuel
Obstruction in fuel pip or air filter
Air exists in fuel system
Nozzle needle was bitted
Obstruction in air filter
Sudden increase of load
4 Causes and Troubleshooting for Exhaust with Black Smoke
CAUSES
Overload
Bad spray
Lack of air or leakage
TROUBLESHOOTING
Check the fuel switch, they should be opened fully.
Clean the fuel filter and fuel pipe.
Check or change the damaged parts of fuel pump.
Adjust the injection pressure
Clean
Clean or change
Change
Remove, clean or change the filter core.
Check the speed of engine with the tachometer, and then readjust
the speed limit bolt.
TROUBLESHOOTING
Fill fuel.
Check or clean.
Emit the air.
Clean, skive the nozzle or change it if necessary.
Check, clean or brush off, or change the filter element
Lighten the load.
TROUBLESHOOTING
Lighten the load; change the matched machine if it does not
comply with the requirements.
Check injection pressure and spray condition and remedy;
change the nozzle if it was damaged.
Clean the air filter; check the cause of leakage and remedy.
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5 Causes and Troubleshooting for Exhaust with Blue Smoke

CAUSES TROUBLESHOOTING
Machine oil mixed in cylinder Check the oil level, drain off the redundant engine oil
Piston ring is clipped, worn or lack of
elasticity, hatch of each ring turned to the Check and replace the piston ring, and cross hatch of each ring
same direction and make engine oil up
Big gap between piston and cylinder Remedy or change
Wear and tear of valve and guide Change

6 Causes and Troubleshooting for Exhaust with White Smoke

CAUSES TROUBLESHOOTING
Water mixed in diesel fuel Clean the fuel tank and filter and change the diesel fuel.

7 Checking Methods when the Engine Encounters Malfunction

CAUSES TROUBLESHOOTING
Speed sometimes fast, sometimes slow Check if the speed governing system is flexible, and if air mixed
in oil pipeline.
Abnormal noise suddenly sent out Stop the engine and inspect each movable parts carefully
Exhaust with black suddenly Check fuel system, especially the nozzle.
Rhythmically metal knocking sound in the The fuel delivery angle is too big, should adjust the angle.
cylinder

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 Chapter 2 Overhaul and Troubleshooting for Diesel Generator

1 Causes and troubleshooting for the generator not being started

CAUSES TROUBLESHOOTING
Lack of diesel fuel Add diesel fuel
Oil switch is not on the position of “ON” Turn oil switch handle to the position of “ON”
(start switch)
No or little spray from injection pump and Disassemble the nozzle and adjust it on the test table
nozzle
The governor handle is not on the position of Turn the governor handle to the position of “RUN”
“RUN”
Check the lubricating oil level The standard of lubricating oil is between upper line “H” and
bottom line “L”
Recoil starter is not swift and powerful Start the engine according to “ Start Operation Procedure”
enough
Dirty in the nozzle Clean the nozzle
No electricity of storage battery Charge up or change the storage battery

2 Causes and troubleshooting for the generator not generating electricity

CAUSE TROUBLESHOOTING
Power switch is on the position of “OFF” Turn the switch handle to the position of “ON”
Bad contact of the socket Adjust the socket pins
Damage of capacitor Change the capacitor

4
Chapter 3 Damage Cause and Remedy of Brushless Alternator
Phenomena Cause
1. Switch is on the position of "OFF".
2. Worse connection of the plug or the
control panel.
3. Circuit break of the coil of the stator;
or the capacitor overloads.
Can not
generate
4. Short circuit of the rectifier.
5. Connection between the coil of the
rotor and the rectifier is wrong, which
can not make the different magnetic
poles (N/S).
1. Low engine speed
2. Short-circuit of the rotor reels.
Low Voltage
3. Short-circuit of the capacitor or the
stator.
1. The rectifier of the rotor got short
circuit by the over-current. The voltage
decreases.
2. After loading, the PTO shaft skids.
Others And the voltage decreases, the
alternator overheats.
3.Short-circuit of the rotor or the stator
makes the alternator overheat. The
voltage decreases.
Remedy
1. Turn the switch to the position "ON".
2. Adjust the contactor of the plug or the
wires inside the control panel.
3.Check the stator at the point of the break;
If it is the just reason that causes problem,
change the stator; Or check the capacitor
with the multimeter, if the needle does not
move, change the capacitor.
4. Check the rectifier by the Multimeter as
the following steps: connect the pens to
each two of the four contactors of the
rectifiers both in the clock-wise way and in
the counter-clock-wise way; if you find that
5. Check the reel and the rectifier by the
Multimeter. Kindly note the current way
while connecting. The correct connecting
diagram is just shown as the right one.
1. Increase the engine speed.
2. Change the rotor.
3. Chang the stator.
1. Check the rectifier as per the above
instruction. Replace a new one.
2. Disassemble the engine. Maintain the
PTO shaft and the inside pole of the rotor
until the conic degree reaches to the
reasonable level. Then assemble the engine.
3. Change the stator or the rotor.
5
Chapter 4 Damage Cause and Remedy of The Brush Alternator
Phenomena Cause Remedy
1. Switch is on the position of 1. Turn the switch to the
"OFF". position "ON".
2. Adjust the contactor of the
2. Worse connection of the plug
plug or the wires inside the
or the control panel.
control panel.
3. The connection of the AVR 3. Connect the contactor well or
contactor is bad or AVR burns. change AVR.
4. The carbon brush wears out
4. Change the carbon brush or
Can not generate or its positive pole and its
make the wrong connection
negative poles are connected
right.
crossly.
5. Check the reel by the
5. The second reel of the
Multimeter. And change the
alternator has turnoff.
stator if it needs.
6. Check the reel by the
6. The rotor has turnoff. Multimeter. And change the
rotor if it needs.
1. Low engine speed 1. Increase the engine speed.
2. Change AVR firstly. If the
2. Short-circuit of the rotor
voltage is not high enough,
reels. AVR burns.
change the rotor.
Low Voltage 3. Short-circuit of the capacitor
3. Chang the stator.
or the staor.
4. Adjust the resistance of AVR.
4. The sample voltage has short
If the voltage remains, change
circuit.
the stator of the alternator
1. AVR burns after load. The
voltage decreases, even 1. Change AVR.
disappear.
2. Disassemble the engine.
2. After loading, the PTO shafts Maintain the PTO shaft and the
skids. And the voltage inside pole of the rotor until the
Others decreases, the alternator conic degree reaches to the
overheats. reasonable level. Then assemble
the engine.
3. Short-circuit of the rotor or
the staor makes the alternator
3. Change the stator or the rotor.
overheat. The voltage
decreases.

6
 Chapter 5 Inspections before Operation and Maintenance

5.1 Inspection before operation

5.1.1 Check the insulated resistance:
An insulated resistance usually results in the creepage of the alternator when it is below
the regulated value and then brings on the security problems. The user should check the
insulated resistance between the master and subordinate reels and the insulated
resistance between the reels and the crust with 500V megohmmeter regularly. The value
should not be under 2 M ohms at normal temperature; otherwise these parts should be
dried. Use the electric cooker, infrared ray or big bulb or something else to heat them up
outside until the insulated resistance reaches the regulated value.
5.1.2 Check the alternator assembly
Make sure all the firming components are tight and the rotor is easy to turn by hand
without impacting, scrubbing and any abnormal noise. Do not let the rain or other liquid
drop into the alternator.

5.2 Starting the generator

The end of voltage output should be on before running the machine. Generator should self
excite, generate voltage in gear and reach the rated power when engine speed is accelerated
to the rated value. Otherwise, stop the machine and check it.

5.3 Maintenance
Keep generator away from the oil, vapor, acidic/alkaline gas, saline brume and do not let
any other solid matter fall into the generator. Keep drafty when the generator is running.
Do not put anything on the surface of generator for baffling ventilation and heat
dispersion. Do not operate under over-loading condition continuously and inspect bolts
and mechanical firming components routinely.

7
 Fuel Knocks (Combustion Noise)
Trouble

Excessive Black Smoke at Idle

Excessive White Smoke at Idle

Excessive-Acceleration Smoke

Excessive Crankcase Pressure

Wear of Bearings and Journals
Hard Starting or Failure to Start

Excessive Smoke Under Load

Cannot Reach Governed RPM

Sluggish Engine Acceleration

Excessive Fuel Consumption

Coolant Temperature too High

Coolant Temperature too Low
Low Power or Loss of Power

Excessive Oil Consumption

Piston, Liner and Ring Wear

Excessive Engine Vibration

Surging at Governed RPM

Worn Valves and Guides

Oil Temperature too High
Shooting

Mechanical Knocks
Crankcase Sludge
Poor Deceleration
Erratic Idle Speed

Gear Train Whine

Excessive Noise
Low Oil Pressure
Engine Misses

Low Air Output

COMPLAINTS
Cummins Engines

Engine Dies

Dilution
CAUSES
Restricted Air Intake l l l l l
High Exhaust Back Pressure l l l l
Air Thin Air in Hot Weather or High Altitude l l l l
System Air Leaks Between Cleaner and Engine l l l l l l
Dirty Turbocharger Compressor l l l l l
Improper Use of Starter Ald/Air Temp. l l l l l

Stuck Drain Valve l l l l l l

Out of Fuel or Fuel Shut Off Closed l l
Poor Quality Fuel/Grade Fuel l l l l l l l l l l
Air Leaks in Suction Lines l l l l l l l l l
Restricted Fuel Lines l l l l l l l l l
External or Internal fuel Leaks l l l l
Plugged Injector Spray Holes l l l l l l
Broken Fuel Pump Drive Shaft l l
Scored Gear Pump or Worn Gears l l
Fuel Wrong Injector Cups l l l l l l
System
Cracked injector Body or Cup l l l l l l l l l l
Damaged Injector O-Ring l l l l l
Excessive Injector Check Ball Leakage l
Throttle Linkage or Adjustment l l l l l l
Incorrectly Assembled Idle Springs l l l
incorectly Assembled Governor Weights l l l
High-Speed Governor Set Too Low l l
Water in Fuel and/or Waxing l l l l l l
AFC Calibration Incorrect l l l l l
Demaged/Worn AFC Pluger Seal/Barrel l
Fuel Pump Calibration Incorrect l l l l l l l l l l
Injector Flow incorrect l l l l l l l
AFC Air Leak, Beloows l l

External and Internal Oil Leaks l l

Dirty Oil Filter l l l l
Faulty Cylinder oil Control l l l l
Clogged Oil Drillings l l l l
Oil Suction Line Restriction l l l l
Lubricating Faulty Oil Pressure Regulator l
System
Crankcase Low or Out of Oil l l l l l l
Wrong Grade Oil for Weather Conditions l l l l
Oil Level Too High l l l l

Insufficient Coolant/Worn Pump l l l

Faulty Thermostats l l l l l
Damaged Hose/Loose Belts l l l

Cooling Internal Water Leaks l l

System Clogged oil Cooler or Water Passages l l
Exterior Leaks/Air in System l l l
Low Coolant Capacity/Dirty Radiator l l l
Coolant Temperature Low l l l l l

Dirty Filters/Screens/Breather l l l l l l
Operation Long Idle periods l l l l l l l l l
and Engine Overloaded l l l l l l
Maintenance Oil Needs Changing l l l l
practices Engine Exterior Dirty l l

Gasket Blow-By or Leakage l l l l l l l l l l l l l l l l

Faulty Damper/Flywheel Balance l l l
Valve Leakage/Adjustment Bad l l l l l l l
Broken or Worn Piston Rings l l l l l l l l l
Incorrect bearing Clearances l l l l l l

Mechanical Excessive Crankshaft End Clearance l l l

Adjustments Broken Cam Lobes l
or Main Bearing Bore Out of Alignment l l l
Repair Engine Due for Overhaul l l l l l l l l l l l l l l
Damaged Main or Rod Bearings l l l
Geartain Backlash/Broken Tooth l l l
Misalignment-Engine to Driven Unit l l l l
Loose Mounting Bolts/Head Capscrew l l
Incorrect Valve and Injection Timing l l l l l l l l
Worn or Scored Liners or Pistons l l l l l l l l
Injectors Need Adjustment l l l l l l l l l l
Broken/Bent Push Rod or Cam Box l l l