Generator Repair & Troubleshooting

Diagnosis and repair guidance for diesel generating sets — starting faults, protective shutdowns, output problems, cooling, fuel and control systems. Written for technicians working on real plant, with the safety constraints stated rather than assumed.

Scope

• ▪Starting and cranking faults
• ▪Protective shutdowns — oil pressure, coolant temperature, overspeed
• ▪Output faults — no voltage, unstable voltage, frequency problems
• ▪Fuel system diagnosis
• ▪Cooling system diagnosis
• ▪Controller and communication faults
• ▪Transfer switching and load acceptance

Diagnosis guides

• Generator Cranks But Will Not Start — Diagnosis and Repair

  Cummins, Perkins, Caterpillar, Volvo Penta, Deutz, Doosan, FG Wilson, SDMO and other electronic or mechanically governed diesel sets

  10 diagnostic steps · intermediate · technician

• Generator Starts Then Stops — Diagnosis and Repair

  Cummins, Perkins, Caterpillar, Volvo Penta, Deutz, Doosan, FG Wilson, SDMO and other electronically or mechanically governed diesel sets

  10 diagnostic steps · intermediate · technician

• Generator Low Oil Pressure Shutdown — Diagnosis and Repair

  All diesel generating sets with oil pressure protection — Cummins, Perkins, Caterpillar, Volvo Penta, Deutz, Doosan, FG Wilson, SDMO and others

  9 diagnostic steps · intermediate · technician

• Generator Runs But Produces No Voltage — Diagnosis and Repair

  Brushless and brushed synchronous alternators fitted to Cummins, Perkins, Caterpillar, FG Wilson, SDMO and other sets. Stamford, Leroy-Somer, Marathon, Mecc Alte and equivalent generator ends.

  10 diagnostic steps · advanced · qualified electrician

• Generator Voltage Unstable or Hunting — Diagnosis and Repair

  Brushless and brushed synchronous alternators with electronic AVRs, on mechanically or electronically governed diesel sets

  10 diagnostic steps · advanced · qualified electrician

• Generator Overheating and High Coolant Temperature Shutdown

  Open and canopied diesel generating sets, single- and three-phase, standby and prime

  8 diagnostic steps · intermediate · technician

• AVR Fault Diagnosis — Before You Replace the Regulator

  Brushless self-excited and PMG-excited alternators on diesel generating sets, single- and three-phase

  8 diagnostic steps · advanced · qualified electrician

• Starter Motor Clicks But Will Not Crank — Diagnosis and Repair

  Diesel generating sets with electric starting, single- and three-phase, standby and prime

  8 diagnostic steps · intermediate · technician

• Generator Starting Battery Not Charging — Diagnosis and Repair

  Diesel generating sets with electric starting, standby and prime, with engine-driven charging alternator and separate mains battery charger

  8 diagnostic steps · intermediate · technician