Fault inquiry

In order to cooperate with users for product maintenance, a fault query form is provided for maintenance personnel's reference.

Failure phenomenon

Possible cause

Exclusion method

Unit cannot start

Insufficient start-up battery capacity of the unit

( 充电、补液 ) 必要时更换此组电瓶 Perform battery maintenance ( charging, rehydration ) if necessary, replace this group of batteries

The control screen is not powered on

Check whether the fuse on the control screen is blown

Start relay failure

Replace this relay

Start motor failure

Analyze the cause and replace if necessary

The unit is stuck and cannot be cranked manually

Examine thoroughly and find out why

Difficult or long startup time

Insufficient start-up battery capacity of the unit

( 充电、补液 ) 必要时更换此组电瓶 Perform battery maintenance ( charging, rehydration ) if necessary, replace this group of batteries

Insufficient warm-up before starting

Checking apricot preheating components

Some ESC units start the throttle potentiometer too small

Refer to the instruction of the random electronic governor, and increase the potentiometer appropriately.

The unit is in a low temperature state

Try to increase the body temperature, it is recommended to use the unit heater

The unit is in a thin air condition on the plateau

Can't start at full speed at one time, you must run at idle for a certain time before rising to full speed

Fuel of the wrong type or grade was used

Must be replaced

Water in fuel

Change fuel, it is recommended to install oil-water separator

Air or no fuel in fuel system

Exhaust the air and let the fuel flow out of the oil return pipe normally through the manual fuel pump

Fuel filter is severely blocked

Change the fuel filter regularly

Severely blocked air intake system

Change the air filter regularly

( 堵塞 ) Failure of fuel injection pump and nozzle ( clogged )

Ask authorized personnel to inspect the oil pump and analyze the reasons, most of which are caused by the use of substandard fuel for a long time

Oil pump failure

Check and repair, replace if necessary

Shutdown solenoid valve failure

Check and repair, replace if necessary

Exhaust system is severely blocked

Check and troubleshoot

Electronic governor failure

Check if power is on and replace if necessary

Cannot keep running after unit start

Water in fuel

Change fuel, it is recommended to install oil-water separator

Air or no fuel in fuel system

Exhaust the air and let the fuel flow out of the oil return pipe normally through the manual fuel pump

Fuel or air filter clogged

二滤Replace the " Secondary Filter " regularly

Insufficient idle time in thin air areas

Properly extend idle time to ensure the unit is warmed up

Use the wrong type or grade of fuel

Fuel must be changed

Easy to overspeed when the unit starts

Electronic speed control unit started the throttle and climbing speed potentiometer improperly adjusted

Refer to the instruction of the random electronic governor, slightly adjust the throttle and climbing speed potentiometer

Setting of overspeed protection value is too small

17 Overspeed protection value is slightly adjusted, the maximum does not exceed 17 %

For mechanical speed control structures

Check the throttle lever for flexibility and make sure it is adjusted correctly

( 系统 ) 故障 Fuel injection pump ( system ) failure

Ask authorized personnel to check and repair

The unit started to emit black smoke

Intake system blocked

Change the three filters regularly

Use the wrong type or grade of fuel

Fuel must be changed

Engine temperature is too low

Wait until the engine reaches normal temperature

Plateau thin air

Plateau engines should run at reduced power

Intake air temperature is too high

40 Intake air temperature should not be higher than 40

Fuel pipe and fuel filter are blocked

Clean fuel pipe, replace fuel filter and primary fuel filter

Turbocharger is heavily worn

Overhaul, replace if necessary

Incorrect valve clearance

Check and adjust valve clearance

Incorrect fueling timing

View fuel injection pump data and ask authorized personnel to repair and adjust

Blue smoke

Excessive engine oil

Check lubricant oil level

Use the wrong type or grade of lubricant

Change lubricants and filters to ensure the correct type of lubricant is used

White smoke

Use the wrong type or grade of fuel

Replace and make sure you use the correct type of fuel

Water leak from cylinder head

Inspect cylinder head and gasket, replace if necessary

The engine has reached the overhaul period

Overhaul engine

Unit cannot reach rated speed

The crew is working in an overloaded state

Reduce the load, not to exceed the rated load of the unit

Electronic governor speed potentiometer is set incorrectly

Refer to the instruction manual of the electronic governor for correct setting or replacement

Electronic speed regulation system failure

Overhaul or give replacement

( 或有松动 ) Improper throttle control adjustment ( or looseness ) of mechanical speed control mechanism

Check and adjust

( 或太细 ) Fuel pipe blocked ( or too thin )

( 更换 ) Overhaul ( replace )

Water in fuel

Change fuel, it is recommended to install oil-water separator

Three filters are not replaced in time

Change the three filters regularly

( 转速 ) 表故障 Frequency ( speed ) meter failure

replace

Crew cruise

Loose mechanical throttle lever

Check and adjust to the correct position

Electronic speed governor

增益 ”“ 稳定度电位器 Refer to the instruction manual of the electronic governor to set the " gain " and " stability " potentiometers

Speed control mechanism is out of control

Ask relevant authorized personnel for maintenance

Fuel system has air or water

( 更换燃油 ) Check and remove (replacement fuel)

Large and frequent load ups and downs

Try to control the load

Unit operation is unstable, vibration

Fuel system has air or water

( 更换燃油 ) Check and exclude ( change fuel )

Air filter blocked

Change the three filters regularly

Too much lubricant, or wrong lubricant grade

Check the lubricating oil level or replace the lubricating oil and filter to ensure that you are using the correct type

Engine intake air temperature is too high

40 Intake air temperature should not be higher than 40

( 或背压过高 ) Exhaust pipe blocked ( or high back pressure )

Reduce back pressure and make engine exhaust easier

( 系统 ) 故障 Fuel injection pump ( system ) failure

Ask authorized personnel to repair

Incorrect valve clearance

Check and adjust valve clearance

Damaged cooling fan

Check and repair, replace if necessary

Unit foundation is uneven, shock absorber installation position is incorrect

Check and adjust position

The service conditions are bad, and the engine enters the overhaul period in advance

Overhaul engine

Lubricant pressure is too low

Lubricant oil level is incorrect

Check lubricant oil level, increase or discharge

Incorrect lubricant brand

Change the correct brand lubricant

Lubricant has not been changed for a long time

Change the lubricant regularly

Lubricant filter clogged

Change the three filters regularly

Extremely high lubricating oil temperature

Inspect or repair or replace the oil cooler

Worn or damaged crankshaft bearings

Overhaul or replace and find the cause

Damaged pressure reducing valve

Replace pressure reducing valve

Oil pan suction filter blocked

Inspect, repair or replace suction pipe and clean suction filter

( 传感器 ) 或仪表故障 Malfunction of lubricating oil alarm switch ( sensor ) or instrument

Check the control panel, meters, body sensors, repair or replace, and troubleshoot

Coolant temperature is too high

Insufficient coolant

Add coolant

Radiator heat sink blocked

Find the cause of the blockage and clean the radiator

Radiator is not well ventilated

According to the installation requirements, increase the effective area of ventilation to ensure smooth ventilation

Cooling fan is not working properly

Check the fan belt tension and replace the belt if necessary

Fan is broken

Overhaul or replacement

Water pump damaged

Overhaul or replacement

Thermostat failure

replace

Fuel injection pump failure

Ask authorized personnel to repair or replace

Fuel timing is incorrect

View fuel injection pump data and ask authorized personnel to repair and adjust

( 进气 ) 温度过高 Ambient ( intake ) temperature is too high

Keep the equipment room ventilated and reasonably reduce the temperature of the equipment room

Crew overload

Control the load and prohibit the unit from overloading for a long time

( 传感器 ) 或仪表故障 Coolant alarm switch ( sensor ) or instrument failure

Check the control panel, meters, body sensors, repair or replace, and troubleshoot

Fuel consumption exceeded

External or internal fuel leak

Check and eliminate leaks

Air filter blocked

Change regularly

Thin air on the plateau

Reduced power operation

Engine temperature is too low

Finding the reason

Crew overload

Control the load and prohibit the unit from overloading for a long time

( 背压过高 ) Exhaust pipe blocked ( back pressure too high )

Check exhaust pipe and control back pressure

Fuel timing is incorrect

View fuel injection pump data and ask authorized personnel to repair and adjust

Incorrect valve clearance

Check and adjust valve clearance

The unit enters the overhaul period

Overhaul unit

Oil consumption exceeded

Lubricant leakage

Check and eliminate leaks

Wrong lubricant type or grade

Change lubricants and filters to ensure the correct lubricant is used

Worn turbocharger seals and bearings

Overhaul or replacement

Worn pistons, cylinder liners, and crankcases

Check the reason and whether it is overhaul

Unit output power is insufficient

Overloaded relative to rated power

Reduced load operation

Low power in plateau areas

1000 米对柴油机功率需修正 Correction for diesel engine power when altitude exceeds 1000 meters

Fuel pipe is too thin or fuel filter is blocked

Check, increase the fuel pipe diameter, reduce fuel pipe resistance, and replace the fuel filter

Use the wrong type or grade of fuel

Change fuel and filters to ensure the correct type of fuel is used

Blocked return pipe or blocked fuel tank vent

Check and troubleshoot

( 背压过高 ) Exhaust pipe blocked ( back pressure too high )

Check exhaust pipe and control back pressure

( 空滤阻塞 ) Insufficient air intake ( air filter blocked )

Change the three filters regularly

( 机房 ) 温度过高 Intake ( machine room ) temperature is too high

Keep the equipment room ventilated and reasonably reduce the air intake temperature

Fuel temperature is too high

<70 Try to control the input fuel temperature <70

Failure of the fuel injection pump or speed control system

Ask authorized personnel to repair or replace

Turbocharger impeller damaged or malfunctioning

Overhaul or replacement

Incorrect valve clearance

Check and adjust valve clearance

Fuel timing is incorrect

View fuel injection pump data and ask authorized personnel to repair and adjust

The unit has entered the overhaul period

Overhaul unit

Unit cannot be shut down

ATS 开机信号切断,机组仍运行 Self-starting unit, ATS start signal cut off, unit still running

It is a normal situation, the unit shuts down after entering the cooling operation

Stop solenoid is out of control

Check wiring is correct, if necessary, replace solenoid valve

( 机械 ) 调速器故障 Electronic ( mechanical ) governor failure

Ask authorized personnel to repair

After the control screen is turned off, press the stop button.

Incorrect operation, you must press the stop button before turning off the key switch

Failure of the fuel tank control instrument

Overhaul or replacement

Unit shutdown

No fuel or water or air in the fuel

Check and eliminate, it is recommended to install oil-water separator

Fuel, air filter blocked

an examination

Electronic governor failure

Ask authorized personnel to repair

Shutdown solenoid valve protects the shutdown action

( 代码 ) ,排除停机故障 Check the alarm content ( code ) to eliminate shutdown failure

( 系统 ) 故障 Unit control screen ( system ) failure

Check the unit control screen according to the instruction manual of the control screen

( 机组闸 ) 故障 Unit distribution circuit breaker ( unit brake ) failure

Automatic trip of air-crew

( 短路 ) 引起的空开跳闸 Open circuit trip caused by unit overload ( short circuit )

Parallel control of electric brake breaking

The switch itself is faulty and must be maintained and replaced

Unit air-closing cannot be closed

( 短路 ) 跳闸后,需再扣才能合闸 After the overload ( short circuit ) trips, it needs to be deducted to close.

Parallel control, cannot be closed without synchronization

Unit brake failure, maintenance or replacement required

Control screen failure

Unit alarm shutdown

( 复位 ) 后重新开机 The control panel detects a unit failure and shuts down, removes the fault, restarts after power failure ( reset )

Mains failure, unit did not start

开机信号,检查排除故障 The ATS control system failed to provide a " power on " signal, check and troubleshoot

自动状态 Self-starting oil meter, must be powered on and working in " automatic " state

The connection of the control line is incorrect. Check and correct the connection.

Failure of self-starting oil meter, maintenance or replacement

The utility power is normal, the unit cannot be shut down

(3 5 分钟 ) Unit is cooling down (3 to 5 minutes )

开机信号没有关闭,检查 ATS 故障 ATS provides " power on " signal without turning off.

The oil meter is incorrectly setting the oil circuit solenoid valve of the unit

Unable to achieve remote monitoring

三遥配置 Confirm whether the unit is configured according to " three remotes "

Check if the communication line is connected correctly

Check if the unit communication software is installed on the control network computer correctly

Whether to set the communication with the correct monitoring password

Control module failure, maintenance or replacement

Troubleshooting principles:
⊙Think first, then do --- understand the structural principle, analyze the failure phenomenon and then check it by hand
⊙ From simple to complex --- start with simple failures
表 From the table to the inside --- check the accessible parts first
故障 Eradicate the fault --- Make sure that the inspections and repairs have been done, and the fault needs to be tested after maintenance. If you are not sure, you need to reproduce the fault test.