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    Trouble Shooting Charts PDF

    Uploaded by

    alekya
    This document provides troubleshooting information for diesel generators, listing various problems, probable causes, and recommended actions. It addresses issues like the generator failing to crank or cranking slowly due to low battery levels. If the generator is cranking but not starting, possible causes include low fuel, a closed fuel valve, or carbon deposits on spark plugs. Running problems may involve a dirty air filter or excess oil. The document also lists common faults such as low battery voltage, improper charging, fuel line air locks, and defective sensors or starters. It provides a simple block diagram of diesel generator components as an overview.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Trouble Shooting Charts PDF

    Uploaded by

    alekya
    210 views7 pages
    This document provides troubleshooting information for diesel generators, listing various problems, probable causes, and recommended actions. It addresses issues like the generator failing to crank or cranking slowly due to low battery levels. If the generator is cranking but not starting, possible causes include low fuel, a closed fuel valve, or carbon deposits on spark plugs. Running problems may involve a dirty air filter or excess oil. The document also lists common faults such as low battery voltage, improper charging, fuel line air locks, and defective sensors or starters. It provides a simple block diagram of diesel generator components as an overview.

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    Trouble shooting charts.pdf

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    This document provides troubleshooting information for diesel generators, listing various problems, probable causes, and recommended actions. It addresses issues like the generator failing to crank or cranking slowly due to low battery levels. If the generator is cranking but not starting, possible causes include low fuel, a closed fuel valve, or carbon deposits on spark plugs. Running problems may involve a dirty air filter or excess oil. The document also lists common faults such as low battery voltage, improper charging, fuel line air locks, and defective sensors or starters. It provides a simple block diagram of diesel generator components as an overview.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    210 views7 pages

    Trouble Shooting Charts PDF

    Uploaded by

    alekya
    This document provides troubleshooting information for diesel generators, listing various problems, probable causes, and recommended actions. It addresses issues like the generator failing to crank or cranking slowly due to low battery levels. If the generator is cranking but not starting, possible causes include low fuel, a closed fuel valve, or carbon deposits on spark plugs. Running problems may involve a dirty air filter or excess oil. The document also lists common faults such as low battery voltage, improper charging, fuel line air locks, and defective sensors or starters. It provides a simple block diagram of diesel generator components as an overview.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    TROUBLE SHOOTING DIESAL GENERATORS

    Probable Cause & Solution


    SNO

    NATURE OF PROBLEM

    ACTION TO BE TAKEN

    A
    A1
    A2

    FAILS TO CRANK
    Low battery.
    Bad battery connection.

    A3

    Blown fuse.

    B
    B1
    B2

    CRANKS SLOWLY
    Low battery.
    Bad battery connection.

    B3
    B4

    Incorrect oil viscosity.


    Load connected.

    Check battery fl uid level.


    Clean & tighten all battery & cable
    connections.
    Replace with recommended viscosity oil.
    Disconnect load before starting.

    C
    C1
    C2
    C3
    C4

    CRANKS BUT WON'T START


    Fuel below generator pickup level in tank.
    Fuel supply shutoff valve closed.
    Carbon deposits on spark plug(s).
    Low oil level.

    Add fuel.
    Fully open fuel supply valve.
    Remove spark plug(s) and replace.
    Add oil.

    D
    D1
    D2

    EXHAUSTING BLACK SMOKE


    Dirty air fi lter.
    Choke stuck or misadjusted.

    UNIT RUNS THEN STOPS WHILE


    RUNNING
    Low fuel level.
    Low oil level.
    Excess oil.

    D1
    D2
    D3
    E
    E1

    UNIT STARTS THEN STOPS WHEN


    THE START SWITCH IS RELEASED
    Low fl uid levels.

    E2

    Possible overheating.

    ACTION
    Check battery fl uid level.
    Clean & tighten all battery & cable
    connections.
    Replace fuse on control panel.

    Replace air fi lter.


    Contact an Cummins Authorized Service O &
    M

    Add fuel.
    Add oil.
    Reduce engine oil level.

    Check & bring all fl uids up to the appropriate


    levels.
    Check for blocked air fl ow or other possible
    causes of over heating

    E3
    E4

    Other functional problem.


    No AC output.

    F
    F1

    UNIT RUNS THEN SURGES


    Loose or worn spark plug leads.

    F2

    Defective ignition coil, wiring, or control


    components
    Governor out of adjustment.
    Combustion air pre-heat malfunction
    Oil filters chocked

    F3
    F4
    F5
    G

    CIRCUIT BREAKER
    Trips

    DG COMMON FAULTS

    H1

    Battery low voltage (cells damage)

    H2

    Contact Authorized Dealer O & M


    Contact Authorized Dealer O & M

    Check plug leads AT ignition coil. Contact an


    Cummins Authorized Dealer O & M
    Remove clean or replace.
    Contact Authorized Dealer O & M
    Contact Authorized Dealer O & M
    Remove clean or replace.

    Overloaded circuit. 1. Turn-off some of the


    electrical load, and reset the circuit breaker.
    To check the bridge rectifier of the charger

    Improper charging

    To check the Float /boost mode of the charger.

    H3

    Fuel line air lock

    H4

    Filter choke/No fuel in tank/ valves are closed

    H5

    Low common rail preassure

    Remove the air lock


    Replace the filter /Fill the tank up to level/ open the
    valves.
    Replace the filter or fill the tank up to the level & fuel
    pump to be check

    Fuel injectors defective

    Injector calibration to be done or replace

    Water seprator choke

    Filter to be replace.

    Self starter defective

    Starter to be repair/ replace

    Self starter saloniod defective

    To be repalace the saloniod

    Fuel filling solonid fault

    To be repair /replace the solonoid

    Fuel level senors fault

    To be replace the sensors

    Turbo charger implier damage

    Specified impeller to be replace

    Turbo charger bearings /bushes damage

    To be replace the bearings/bushes

    Radiator fills damage

    Adjust the fills, if nessary replace.

    Radiator fan motor defective (for D.G.-1 only)

    To be replace / replace the motor.

    H6
    H7
    H8
    H9
    H10
    H11
    H12
    H13
    H14
    H15
    J
    J1
    J2
    J3
    J4
    J5
    J6
    J7

    DG HUNTING
    Filter choke

    Filter to be replace.

    Dust particals in the fuel tank/line

    Clean the tank/Line

    Sensors loose connection

    To be tighten the connections.

    Radiotor belt damage

    To replace the belts

    Air Filter chocked

    To be clean the filter

    Lack of coolent

    Fill the coolent

    Coolent pump defective

    Pump to be repaired & replaced

    J8
    J9
    J10
    J11
    J12
    K
    K1
    K2
    K3
    K4
    K5
    L
    L1
    L2
    L3
    L4
    M
    M1
    M2
    M3
    M4
    M5
    M6
    M7

    Low oil level

    To fill the oil up to the level

    Radiotor fan damage

    Replace

    Oil leakage

    o' Ring to be replaced

    Radiotor choke

    Clean the raditor

    Exhaust smoke leakage

    Repair

    BATTERY NOT CHARGING


    Battery sulpher formation

    Clean the terminals and apply the petroleum jelly

    Dynamo defective

    To be repair/replace

    Dynomo belt damage

    Replace the belt

    Charger failure

    To check the charger

    Terminals loose contact

    Trminals to be tightened /Lugsto crimp properly

    POOR OIL PRESSURE


    Low oil level in sump

    To fill the oil up to level

    Oil pump defective

    To be repaired/replace

    Lub oil filter chocked

    To be replaced

    Lub oil pump sterner defective

    To be replaced

    LEAKAGES
    Cylinder head gas cut damage

    Gasket to be replace

    Oil sump gas cut damage

    Gasket to be replace

    Turbo charger hose oil leakage

    Hose to be replace

    Fly wheel seal damage

    Seal to be replace

    Engine block dummy seals damage

    Specified seal to be replace

    Radiator tube damage

    Repair the radiotor tubes

    fuel hoses damage

    Specified fuel hases to to be replace

    SIMPLE DG BLOCK DIAGRAM

    SIMPLE DG

    SIMPLE DG BLOCK DIAGRAM

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