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SELECTION OF SITE

FOUNDATION DETAILS AND GUIDELINES

EARTHING SYSTEM

EXHAUST PIPING

FUEL PIPING

CABLING

BATTERY CHARGING PROCEDURE

SUMP CAPACITY (LITRES)

CHECK UP BEFORE STARTING THE DG SET

PRE-COMMISSIONING CHECK

ROUTINE CHECK POINTS

DO'S & DON'T'S

TROUBLE SHOOTING - ENGINE

TROUBLE SHOOTING CHART : ALTERNATOR

TROUBLE SHOOTING GUIDE FOR MANUAL PANEL

TROUBLE SHOOTING GUIDE FOR AMF PANEL

TROUBLE SHOOTING - ENGINE

Trouble

Cause Cause

Redress

Engine dose not start

No fuel in tank./ Air in fuel

system./In sufficient speed of
starter

Fill in fuel, vent fuel system. / Vent fuel system. / Charge

batteries.

Engine does not start at temperatures

below 0 C

See above or the ready to start /

signal lamp does not light

Of above , or change lamp.

Defect of series resistor solenoid /

valve, or flame heater plug /
Paraffin precipitation of fuel

Heat up fuel Pipings, change / Filter

Fuel tank cock closed. / Dirt in

primary fuel cleaner or in fuel
filter. / No fuel in tank, no
conveyance of fuel.

Open cock / Clean or change filter cartridge respectively /

Fill in fuel , vent fuel system. of fuel. inspect correct operation
pump, replace if necessary, and check safe venting of tank.

Engine starts up but stops after brief time

No power and misfiring of engine

Water or dirt in fuel system. /

Clean fuel tank, fill in clean fuel replace filter, and vent fuel
Interruption of air supply or heavy system.
jamming of air filter. / Air in fuel
/ Inspect, replace if necessary or clean. / Vent fuel system /
system / Fuel filter jammed.
Change filter
Starts of fuel supply missed /
Defect of exhaust brake.

Reset start of fuel supply. / Inspect and repair

Engine emits white or bluish fumes,

Retorted and start of fuel supply

Set correct start of fuel supply

Trouble

Cause

Redress

Engine is still cold. / Mis setting of Permit engine to heat up in operation / Check start of fuel supply
fuel injection system.
inspect injectors.
Engine emits black fumes.

Engine is overloaded.

Reset fuel injection system / consult workshop.

Air filter jammed. / Fuel injection

piping loose or broken.

Change air filter element. / Tighten fuel injection piping or

replace it, respectively.

Heavy knocking of engine.

Engine grows excessively hot.

Starts of fuel supply too early /

Mis-setting of valve air gaps /
Mechanical defects of engine

Set correct start of fuel Supply / Adjust & correct valve air gaps. /
Consult authorised workshop

Slipping of V-Belts. / V-belts

broken. / Defect of temperature
governor. / Defect of temperature
Tighten or Replace V-belts. / Replace V-belts. / Emergency
Controller / Lack of coolant. /
operation; forced opening of valve plate./ Perform electrical
Radiator is dirty. / Mis-setting of check of temperature controller./ Fill in coolant. / Clean radiator. /
fuel supply. / Intake or exhaust
Set correct engine in fuel supply / Redress cause of trouble. /
system jammed / Heavy dirt
Consult workshop.
accumulation on sylinder
elements

Trouble

Cause

Redress

Irregular speed of engine.

Defect of speed governor.

Inspect fuel injection pump and governor

Excessively high fuel consumption

Mis-setting of fuel injection system

Check, fuel injection system

Injection of excessively great fuel

quantity engine emits black fumes
Have fuel injection pump adjusted by specialised workshop. /
/ Leakage of solenoid valve of
Replace solenoid valve. /
cold starting device. / Jammed air Replace air filter. / Consult authorised workshop / Consult
filter. / Engine is worn. / Defective workshop.
exhaust brake.
Very low oil Pressure.

Jammed paper filter cartridge.

Replace paper filter cartridge.

Deficient oil level. / Pressure

gauge or pressure gauge tube
loose or defective / Leakage in oil
Check and add oil. / Inspect and replace ortighten. / Check. /
system. / Improper lube oil
Check brand of oil. / Replace valve. / Consult authorised workshop
(viscosity). / Defect of control valve
for cooling of pistons. / Heavy
wears of bearings.
Increase in lube oil consumption

Leakage in oil system. /

Excessively high oil level.

Inspect pipings, filters, and ducts for tightness. / Defect of air filter
system, and cooling of pistons, consult authorised workshop.

Trouble

Cause

Redress

No dirt deposits centrifugal filter

Rotor jams.

Inspect rotor bearings, inspect oil supply to rotor.

Heavy blowing from venting hose of

engine.

Excessively high oil level,

damages of cylinder elements.

No air supply from piston or compressor.

Defect of cylinder element or of

valve plate.

Consult authorised workshop.

Battery charging signal lamp alight while

ignition is switched off.

Defective insulation in fanned

cable

Consult authorised workshop

Battery charging signal lamp does not

light up when ignition is switched on

Defect of signal lamp. /

Interruption of D* governor and
generator / Battery discharged

Replace signal lamp. / Plug in connector./ Change battery.

Battery charging signal lamp alight

during normal operation

Broken V-belt. / Defective

alternator.

Replace V-belt. / Inspect or consult workshop.

Heavy boiling of battery.

Defective governor, excessive

contact resistance of negative
polarity across brush holder and
end shield bearing of generator.

Consult authorised workshop.

Starter does not run.

Battery discharged.

Charge battery.

Deficient speed of starter

Starter terminal voltage too low.

Check battery cells,recharge battery.

Oxidized or loose terminal

connections

Clean and fasten terminals.

Carbon brushes jam or are worn.

Clean or replace brushes.

Adjust oil level, consult

authorised workshop.