In the reports of unit malfunctions received, they are often caused by some basic malfunctions. As long as daily maintenance and preventive measures are mastered, many problems can be avoided. So, what are the common faults and troubleshooting measures for diesel generator sets and control systems?

Fault phenomenon one:

The controller has no water temperature/oil pressure/liquid level and displays "# # # #".

Possible measures:

Check if the temperature/oil pressure/liquid level sensors and their wiring "G" and "WK" of the controller are reversed.

Fault phenomenon two:

The controller displays inaccurate water temperature/oil pressure/liquid level data.

Possible measures:

Check if the curve type of the temperature/oil pressure/liquid level sensor in the controller matches the selected sensor.

Fault measure three:

The controller displays unstable data on water temperature, oil pressure, and liquid level.

Possible measures:

1. Ground the common end of the sensor on the controller to the grounding pile head of the generator set.

2. Check if the negative terminal wire diameter of the unit starter is too thin, causing voltage changes during startup.

Fault phenomenon four:

The output port of the controller always burns out during startup.

Possible measures:

The internal starting relay of the controller has a small volume and limited current capacity, but the current of the unit during startup will be 2-3 times that of the relay. Short term startup can still withstand it, but long-term repeated startup of relay contacts can easily cause adhesion, so it is necessary to add a relay when starting.

Fault phenomenon five:

If there is no rotational speed during startup, it will display "Orpm" or no display.

Possible measures:

Check if the speed sensor body and screw in position are too far from the flywheel disk, check the wiring, and check the successful starting conditions set by the controller.

Fault phenomenon six:

If there is no idle or direct overspeed of the generator set, the controller will report an "overspeed alarm shutdown".

Possible measures:

1. Check if the programmable output port of the controller is configured.

2. Determine whether the unit is equipped with electronic speed control or mechanical cable speed control.

3. Check the external electronic speed control or mechanical cable speed control.

4. Check if the idle timing of the controller is "OS".

5. Adjust the rated speed of the electronic speed controller and adjust the potentiometer counterclockwise to reduce the speed.

Fault phenomenon seven:

The generator set cannot enter high speed, and the controller reports an "underspeed alarm shutdown".

Possible measures:

1. Check if the idle control output port of the controller is disconnected after the idle timing.

2. Check if there are any faults and wiring in the electronic speed controller.

3. Check if the rated speed of the electronic governor is adjusted too low.

4. Check if the acceleration time adjustment of the electronic speed control board is too large.

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