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Reasons for The Generator Set Start Failure

Jul. 29, 2021

In daily work, the most common phenomenon of a generator set is that it cannot be started, which causes special equipment to fail to operate normally. Vibration occurs when the generator set is running, which will loosen the wiring and cause poor contact, which will also make the generator set unable to start normally. If you press the genset start button, the genset rotates slowly, showing that it is weak or unable to rotate, you should check the battery immediately. The most common reasons why the genset cannot start are as follows:

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1. Check whether the positive and negative cable connections of the starting motor are firm.

The probability of failure of the starting motor itself is less, but it cannot be ruled out. To determine the action of the starting motor, you can test the shell of the starting motor with the back of your hand when you start the diesel engine unit. If the starting motor is static and the shell is cold, it means that the motor is not moving. Scientific papers, if the diesel generator set or starter motor is severely hot and has an irritating scorching smell, the motor coil has been burned. It takes a long time to repair the motor and it is recommended to replace it directly.


2. Battery failure.

Use a multimeter to check whether the battery voltage reaches the rated voltage of DC24V, because when the generator is in an automatic state, the electronic control module ECM monitors the status of the entire unit and the communication between the EMCP control panel is maintained by the battery. When the external battery charger fails, or the internal self-discharge of the battery will cause the battery power to not be replenished and cause the voltage to drop. At this time, the battery must be charged. The charging time depends on the discharge of the battery and the rated current of the charger. If the situation is urgent or the battery cannot be charged or stored, the battery must be replaced.


In view of the above situation, it is recommended to equip the generator set with a fully automatic special charger to ensure that the battery maintains a constant voltage at all times. In addition, make a voltage measurement on the battery at least once a week. For wet-type batteries, it is necessary to check the battery water from time to time to see if it is between the minimum and maximum scale lines, otherwise adjustments must be made to avoid insufficient charging of the battery or liquid overflow during charging. If the usual improper maintenance causes the loss of water and acid components in the battery to not be replenished in time, it is easy to reduce the battery capacity and reduce the service life of the battery.


3. Check whether the battery terminal is in good contact with the connecting cable.

If the battery electrolyte is supplemented too much during normal maintenance, it will easily overflow the battery surface and corrode the terminal, increase the contact resistance and make the cable connection poor, which may also make the generator set unable to start. In this case, it is recommended to use sandpaper to polish the corroded layer of the terminal and the cable joint, and then re-tighten the screws so that the terminal and the electrode wiring are in full close contact. In order to avoid re-corrosion of the terminal, grease can be applied to the terminal for anti-corrosion treatment.


4. The failure of the fuel supply system causes the generator set to fail to start.

For example, there is air entering the fuel system. This is a common fault. It is usually caused by improper handling when replacing the fuel filter element (such as not performing exhaust work after replacing the fuel filter element). After the air enters the pipeline with the fuel, the fuel content in the pipeline is reduced, and the pressure is lowered. The high-pressure fuel injection atomization of the nozzle is not enough to enable the injector to open the nozzle to reach 10297Kpa or more, and the engine cannot be started. Exhaust treatment is required at this time (Jiangsu Xingguang diesel generators need to be exhausted with a hand pump), and only when the inlet pressure of the fuel delivery pump reaches 345Kpa or more. In addition, the blockage of the fuel pipeline, such as the blockage of the fuel injection nozzle, will also prevent the generator set from starting. At this time, the fuel circuit must be cleaned to make the fuel circuit unblocked and the generator set can be started.

5. The failure of the air filter causes the generator set to fail to start, which is also relatively common.

This situation is generally due to neglect of management by the staff and infrequent maintenance of the generator set. The air filter has not been cleaned for a long time, and there are too many sundries such as dust. As a result, the air cannot be supplied to the diesel engine and the generator set cannot start normally. At this time, the air filter needs to be cleaned or replaced, and the fault can be eliminated.

Starlight Power was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. If you want get more information, welcome send email to sales@dieselgeneratortech.com we will pay highly attention on your question.

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