DA NANG UNIVERSITY

UNIVERSITY OF SCIENCE AND TECHNOLOGY INSTITUT

POLYTECHNIQUE DE DANANG

Major Essay: Analysis of working and maintenance characteristics parameters of a

stationary dynamics system
Lecturer : Dr. Le Minh Duc
Class : 21N17
Group : 10
Students : Vo Anh Tai - 103210130
Le Phan Cong Tan - 103210131
Huynh Van Thien - 103210133
Tram Phuoc Thien - 103210134
Nguyen Van Tien - 103210135

Da Nang 16/5/2024
Introduction
The stationary propulsion system engine has become an essential part of modern life,
playing a crucial role in providing energy for daily activities. One popular type of
stationary propulsion system is the diesel engine used for power generation. Diesel
engines used for power generation employ the operating principles of diesel engines to
produce electrical energy.
The utility of diesel engines for power generation is diverse and beneficial in daily life.
They are widely used in construction sites, power stations, apartment buildings, schools,
hospitals, and various industries. In the event of a power outage, diesel engines for power
generation will automatically operate to provide backup power, ensuring the continuous
operation of important devices and systems.
One famous and noteworthy model of diesel engine for power generation is the
Mitsubishi 650KVA engine. Mitsubishi is a brand from Japan. It is a good quality brand.
Especially very trusted and chosen for use in Vietnam.
The Mitsubishi 650KVA generator, utilizing S6R2-PTA-C engine. With a capacity of
650KVA, this generator is capable of supplying sufficient energy to serve multiple
devices and systems in a large area. The Mitsubishi 650KVA engine is designed for
efficient and durable operation, ensuring continuous and stable power supply. In addition,
with reasonable prices, Mitsubishi 650KVA generators are being widely used in private or
foreign-invested projects such as industrial factories, office buildings and hotels..
I. SPECIFICATIONS OF MITSUBISHI 650KVA GENERATOR
1. Basic specifications of Mitsubishi 650KVA

Figure 1: Mitsubishi Generator 650 kVA

Table 1: Parameter Table Of The Generator
Parameter Mitsubishi 650KVA
Generator Powered by Diesel 3 Phase Alternating
Assembly AGG Power Solutions (China)
company
Model MS715D5
Capacity Prime 650KVA
Standby 715KVA
Voltage, 230/400V, 3 phase – 4 wire, 50 Hz
frequency
Voltage stability ± 1%
Engine Model S6R2-PTA-C – is a product of Mitsubishi (Japan) jointly
manufactured in Shanghai, China
Player Model TAL-A473-F – produced by Leroy Somer (France) in
Fujian, China
Remote controll Model DSE7320, produced by Deepsea (UK) in the United
Kingdom
Soundproof shell Imported as a complete set with the machine or manufactured in
Vietnam
Size machine Length 3560mm – Width 1420mm – Height 2020 mm
Fuel 136 liters per hour at 100%
consumption
Operation mode Automatic operation or manual control
2. Specifications of S6R2-PTA-C

Figure 2: Generator S6R2-PTA-C Engine

Table 2: Parameter Table Of S6R2-PTA-C Engine
Parameter S6R2-PTA-C engine
Engine type Diesel 4 stroke with turbocharger
Manufacturer Mitsubishi Shanghai (SME)
Model S6R2-PTA-C
Origin China
Maximum power 635 kW
Radiator cooling Type 50C water tank
Number of cylinders 6 cylinders in-line
Piston journey 220 mm
Cylinder diameter 170 mm
Cylinder capacity 29,96 l
Compression ratio 14:1
Lubricating oil 84 l
capacity
Fuel injection type Direct
Speed controller Electronic
II.
2. Describe main parts of generator structure

2.1. Engine
- The Mitsubishi China 650 kVA generator uses the S6R2-PTA-C engine manufactured at
the Mitsubishi Shanghai factory (SEM) - a joint venture of Mitsubishi (Japan) in
Shanghai, China.
- S6R2-PTA-C is equipped with 6 cylinders arranged in line, with a maximum capacity of
up to 635 kW (792 kVA) helping the MS715D5 be ready to meet a maximum load of 715
kVA. In addition, the engine is equipped with a 500C water tank suitable for the hot
climate in Vietnam.
PRINCIPAL PARTICULARS
Model MITSUBISHI S6R2 – PTA – C
Type 4 cycle stroke, water cooled diesel
engine
Combustion chamber Direct injection type
Aspiration Turbocharged with after cooler
Number of cylinders 6–L
Bore x stroke 170mm x 220mm
Total displacement 29.96L
Compression radio 14.1 : 1
Firing order 1–5–3–6–2–4
Direction of rotation Counter clockwise as viewed from
flywheel side
Engine dimensions Length Apx. 1945.5mm
Width Apx. 1050.5mm
Height Apx. 1578mm
Dry weight Apx. 2900kg (without accessories)

2.2. Alternator
- The MS715D5 unit uses the generator model TAL-A473-F from Leroy Somer (France)
manufactured at the Leroy Somer factory in Fujian, China.
- The TAL-A473-F generator is a brushless automatic generator, automatically adjusting
voltage through AVR with ±1% voltage stability to ensure safety for consuming devices
(electricity).
Basic parameter table of Leroy Somer/TAL-A473-F player:
Manufacturer Leroy Somer (France)
Model TAL – A473 – F
Origin China
Power 650 kVA
Voltage, frequency 230/400 V, 50 Hz
Number of phases and wires 3 phase, 4 wires
Voltage stability ±1%
Power factor 0.8
Insulation level H level
Protection level IP23

2.3. Control Panel

- The MS715D5 unit uses the model DSE7320 controller manufactured by Deepsea (UK)
in the UK. DSE7320 is a smart control type that automatically supplies power after 20
seconds (from receiving the power failure signal).
- The entire operation of the machine is through the DSE7320 controller: Turn on/off the
machine, view the machine's operating parameters on the screen. In addition, the
DSE7320 also has a safety protection function for the machine - automatically stopping
the machine when safety parameters exceed allowable thresholds.
Basic parameter table of Deepsea DSE7320 controller
Manufacturer Deepsea (UK)
Model DSE7320
Display screen LCD 3.5 inch
Parameter display:
Display operating parameters of the
machine: Power (kVA); Voltage (V);
Frequency (Hz), Fuel level (%); number
of hours of operation;...
Function Warning:
The controller will issue warning signals
when the parameters are about to exceed
 the safety threshold.
Stop the machine:
To protect the safety of the machine, the
controller will order the machine to stop
when the operating parameters exceed
the warning threshold.
Connect Connect to ATS cabinet
Connect to a computer (PC)

2.4. Frame/ Housing

- The engine frame is the part that supports all other parts of the generator. The
Mitsubishi 650KVA machine frame is made of sturdy steel, resistant to vibration and
noise.
- The entire frame is powder coated, qualified for outdoor use.
- Imported synchronously by machine or manufactured in Vietnam
2.5. Accessories included
– The MS715D5 device is equipped with the following accessories:
+ Starting battery pack: Includes 2 120Ah maintenance – free dry batteries, products of
Varta (Germany ) manufactured in China.
+ Battery charger: Automatic charger (compensator) input from mains voltage 220 VAC,
output 24 VDC, 3A. Manufactured by Smartgen (China).

+ Rubber damping between the engine and the base frame

+ 50 degree Celsius water tank

+ Water separator protects the engine

+ Fuel filler cap and level gauge

III.
1. Fuel System
1.1. Duties of the fuel system:
- Fuel Storage: The fuel system provides a secure container, typically the fuel tank, to
store the fuel safely and efficiently. This tank is designed to prevent leaks and maintain
fuel quality until it's needed by the engine.
- Fuel Delivery: The system then takes care of transporting the fuel from the tank to the
engine. This involves components like the fuel pump that pressurizes the fuel and pushes
it through the fuel lines.
- Fuel Filtration: Before reaching the engine, the fuel needs to be clean. The fuel system
incorporates filters to remove dirt, debris, and other contaminants that could harm the
engine's delicate parts. Clean fuel ensures smooth engine operation and prevents damage
to injectors or carburetors.
- Fuel Metering: The amount of fuel delivered to the engine needs to be precise for
optimal performance and efficiency. The fuel system uses components like injectors or
carburetors to precisely meter the fuel based on engine demands. This ensures the engine
gets the right amount of fuel for the current power needs.
- Fuel System Integrity: The fuel system also plays a role in maintaining proper pressure
and preventing leaks. Leakage not only wastes fuel but can also pose safety hazards. Fuel
system components are designed to be durable and well-sealed to ensure proper fuel
delivery and prevent leaks.
1. 2. Requirements for fuel system:
– Must automatically provide the amount of fuel appropriate to the load mode and engine
rotation speed.
– Provide fuel evenly to the cylinders in accordance with the engine's working order.
– Inject fuel into the cylinder at the right time and according to the rules.
– Fuel must be shredded, evenly distributed in the cylinder volume and the fuel jet must
conform to the shape of the combustion chamber.
1. 3. Diagram of the fuel system in a diesel engine

a. Fuel tank
- The fuel tank is used to store the amount of fuel necessary for the engine to work
continuously for a certain period of time. Normally in a diesel generator set, the fuel tank
has enough capacity for the machine to operate for 8-10 hours continuously.
b. Fuel Filter
- The diesel engine for the generator will be equipped with 2 fuel filters: a coarse filter
and a fine filter.
- The coarse filter is used to pre-filter large mechanical impurities from the fuel, before
the fuel is transferred to the push pump (the pump transfers fuel from the fuel tank to the
fuel system). The coarse filter is capable of filtering impurities 0.04-0.09 mm in size.
- The fine filter is used to thoroughly filter mechanical impurities contained in the fuel
before sending the fuel to the high-pressure pump.
c. Feed pump (also known as low pressure pump)
- The push pump is used to suck fuel from the tank through the coarse filter into the fine
filter with a certain pressure. The most common pump is the piston pump.
d. Injection pump (also know as high pressure pump)
- The high-pressure pump has the role of compressing diesel oil at high pressure (up to
1000 kg/cm 2 ) to push fuel to each injector, ensuring enough flow and the right time to
inject fuel.
e. Injection nozzle
- The injector receives high-pressure fuel from the high-pressure pump to spray into the
combustion chamber of the engine cylinder into small mist-like particles. The
requirements for the nozzle are to ensure even spraying, no dripping, and the fuel sprayed
into the combustion chamber must be fine mist.
2. Lubrication system
2.1. Duties of the lubrication system
- The diesel engine's lubrication system is responsible for providing clean lubricating oil
in the necessary amount at a certain temperature and pressure to the friction surfaces of
machine parts when the engine is working.
- More specifically, lubricating oil will reduce friction loss and wear of machine parts;
cooling of surfaces by friction; clean soot and metal filings produced by worn machine
parts on working surfaces; At the same time, it protects machine parts from oxidation and
increases the tightness between assembled pairs.
2.2. Requirements for lubrication system
- Deliver a continuous and uniform supply of lubricant:The system should be able to
provide a consistent flow of lubricant to all the necessary parts of the machine at the
appropriate rate. This ensures that there is always enough lubricant to prevent wear and
tear.
- Maintain proper pressure: The pressure of the lubricant should be high enough to
overcome friction and deliver the lubricant to all the required areas. However, it should
not be too high as this can lead to energy waste and power loss.
- Cleanliness: The lubricant needs to be clean and free of contaminants. Contamination
can increase wear and tear on machine parts. The lubrication system should include filters
to remove contaminants from the lubricant.
- Reliability: The lubrication system should be reliable and function properly over a long
period. This means that the components of the system should be durable and well-
maintained.
- Compatibility: The lubricant used in the system must be compatible with the materials
of the machine parts. Incompatible lubricants can damage the machine.
2.3. Diagram of the lubrication system

a. Oil pump
- This is the part responsible for providing lubricating oil to the surfaces that need
lubrication in the engine. Oil pumps can be gear, vane, piston or centrifugal, operating on
the principle of creating pressure to push oil.
b. Oil strainer
- Oil strainer act as a first line of defense, catching larger contaminants like dirt, debris,
metal shavings, or worn-out particles before they reach the main filter.
c. Oil filter
- Oil filter is a full-flow filter which reigns supreme as the primary guardian of clean oil.
It's the workhorse responsible for removing contaminants that could harm engine.
- Oil filter continuously cleans all the lubricant circulating in the system. It traps
contaminants like dirt, wear debris, metal shavings, and other impurities that can cause
friction, accelerate wear, and ultimately damage machine components.
d. Bypass oil filter
- Unlike the main filter, which cleans all the lubricant circulating in the system, a bypass
filter only cleans a portion of the oil flow.
- It's essentially a secondary filtration stage that works when the main filter gets clogged
or when there's a high pressure surge in the system.
e. Safety valve
- A safety valve acts as a pressure relief valve. It safeguards the lubrication system from
dangerously high pressure buildups.
- The valve remains closed during normal operation when oil pressure stays within the
designated safe range.
f. Relief valve
- Similar to safety valves, relief valves act as pressure control devices. Their primary
function is to regulate pressure in a system by releasing excess fluid when it surpasses a
predetermined level.
- Unlike safety valves, which typically only operate in emergency situations, relief valves
can also be used for normal system operation. They can open and close more frequently
to maintain pressure within a desired operating range.
g. Oil cooler
- The oil cooler is responsible for cooling the lubricating oil when the oil temperature is
too high. Lubricating oil during operation will absorb heat from moving parts, leading to
an increase in temperature. If the oil temperature is too high, the oil will decompose and
lose its lubricating ability. Therefore, the oil cooler will help lower the oil temperature to
a suitable level to ensure effective lubrication.
h. Main oil gallery
- It's a network of passages drilled or cast directly into the engine block, cylinder head,
and sometimes even the crankshaft.
- The main oil gallery acts as the oil's highway, serving as the primary channel for
delivering pressurized oil from the oil pump to various critical engine components.
3. Cooling System
3.1. Duties of the cooling system
- The duties of the cooling system is to dissipate heat from the engine's parts while
working, keeping the temperature of the parts from exceeding the allowable value to
ensure normal working conditions of the engine. .
- For diesel engines, generators will be cooled using the forced circulation cooling
method (a closed loop).
3.2. Requirements for cooling system
- Heat Dissipation Capacity: The core requirement of a cooling system is to remove
excess heat effectively. It needs to be able to absorb the heat generated by the engine or
machine and transfer it away to the surrounding environment
- Efficient Heat Transfer: The system should excel at transferring heat from the hot
source (engine) to the coolant and then from the coolant to the surrounding air or another
cooling medium. This efficient heat transfer relies on good thermal conductivity of the
materials used in the system's components.
- Temperature Regulation: The cooling system must maintain the engine or machine
within a specific optimal operating temperature range. This is crucial for peak
performance, fuel efficiency, and preventing wear and tear on components. A thermostat
is often used to regulate coolant flow and ensure the engine reaches its proper operating
temperature quickly and stays within the desired range.
- Proper Coolant Circulation: To achieve efficient heat transfer, the system needs to
ensure a consistent and adequate flow of coolant throughout the engine or machine. This
circulation is typically maintained by a coolant pump that forces the coolant through the
system.
- Leak Prevention: A well-maintained cooling system should be free of leaks. Leaks can
lead to coolant loss, reduced system effectiveness, and potential engine overheating.
- Maintainability: The cooling system should be designed for easy maintenance and
inspection. This allows for timely replacement of worn-out components and ensures the
system's continued effectiveness.
3.3. Diagram of the cooling system
a. Water pump
- The water pump is responsible for propelling the coolant throughout the entire engine
cooling system. This continuous circulation is essential for absorbing heat from the
engine block and cylinder head, the areas that generate the most heat during operation.
b.Water jacket
- The water jacket's primary function is to provide a direct path for the engine coolant to
circulate around the hottest parts of the engine. This close contact allows the coolant to
absorb heat effectively from the engine block and cylinder head, preventing them from
overheating.
c. Radiator
- The radiator's primary function is to transfer heat away from the engine coolant. It
acts as an intermediary between the hot coolant and the surrounding air. As the coolant
travels through the radiator's thin tubes, air flows through the fins, facilitating heat
exchange.
d. Thermostat
- The thermostat controls the direction and amount of coolant circulating through the
engine.
- When the engine is cold, the thermostat remains closed, restricting coolant flow to the
radiator. This allows the engine to warm up faster and reach its ideal operating
temperature quicker.
- Once the engine reaches its designated operating temperature, the thermostat gradually
opens. This allows the hot coolant to flow freely to the radiator, where the airflow helps
dissipate heat and cool the coolant down.
- As the engine temperature fluctuates during operation (due to increased load or changes
in ambient temperature), the thermostat constantly adjusts its opening and closing to
maintain a stable temperature range.
e. Bypass pipe
- When the engine is cold, the thermostat remains closed. This restricts the flow of
coolant to the radiator. However, the bypass pipe provides an alternative path for the
coolant to circulate directly to the water pump without passing through the radiator and
continuing to cool throughout the engine.
4. Starter System
- To start a diesel engine, it is necessary to provide energy to rotate the engine crankshaft
to the necessary rotation speed (about 125-200 rpm) for the engine to start and work on
its own.
- The MS715D5 unit uses an electric motor starting system to rotate the engine's
crankshaft with an electric motor powered by direct current supplied by the battery. The
shaft of the starter is connected to the crankshaft of the engine through a pair of
transmission gears.
- In diesel engines, the capacity of the starter is usually equal to 5-15% of the capacity of
the entire diesel engine.
5. Inlet and Exhaust System

- Duties of the exhaust system:

+ Providing the right amount of intake air for the engine: The intake and exhaust system
ensures the necessary amount of intake air is provided for the engine to operate in all load
modes, helping the engine operate efficiently and save fuel.
+ Cooling the intake air: Cooling the intake air helps increase intake air density, improve
combustion efficiency and reduce harmful emissions.
+ Clean intake air filter: Air filter system removes dirt and impurities in the air, protects
internal engine parts from damage and increases engine life.
+ Noise reduction: Mufflers help reduce noise caused by exhaust gases leaving the
engine, contributing to environmental protection and creating a safer working
environment.
6. Turbochager

- The primary function of a turbocharger is to increase the air intake of an engine. This
additional air, when combined with the proper amount of fuel, leads to more combustion
and, consequently, more power output.

IV. 4. Working modes

4.1. Inspect Before Operation
4.1.1. Pre‐heat
The generator set is equipped with a heater for the water jacket. Purpose to
Installing the preheater is to ensure that the generator set can be started at low
temperatures
temperature and some emergencies, at the same time it can also stop the generator set
from being damaged by cold winter weather.
4.1.2. Inspect Before Operation
Operate the generator set without load once each week for 20 minutes. If the generator
set is not connected to an automatic transfer switch (ATS) with an exercise option,
exercise the unit in the presence of an operator. The operator should perform all of the
prestart checks before starting the exercise procedure. Start the generator set according to
the starting procedure in the controller section of this manual. While the generator set is
operating, listen for a smooth-running engine and visually inspect the generator set for
fluid or exhaust leaks. Check the air inlets and outlets and remove any items restricting
the air flow. After finished installation, our diesel engine generator set can be put into use.
Each time before starting the generator set, following items shall be checked without fail.
1. Make a general visual inspection on the engine and alternator. Check if there is any
breakage, crack, indentation, leakage or looseness. Never operate the generating set
before removing any fault, if any.
2. Take out foreign materials such as keys, tools, cleaning wool, papers etc. on the engine
and the alternator.
3. Check the fuel level in the tank, refill with fuel if it is low.
4. Control the abrasion in the charge alternator belt and check periodically the belt
tension according to producer' recommendation.
5. Check the oil level on the dipstick. Refill with an appropriate oil if it is low. Maintain
the oil level at or near, not over, the full mark on the dipstick.
6. Look at the water level by opening the radiator tap. If it is inadequate add more water.
Water level must be 30 mm lover than the water filling neck. Engine cooling water must
include antifreeze according to the coolest weather conditions in the area.
7. A mixture of antifreeze and water provides a good protection in all area. For antifreeze
and water percentage refer to manufacturer requirements.
8. Inspect the radiator air outlet hood, open if clogged and clear away all obstructions in
front of the air outlet
9. Check the air filter. If the air filter is fitted with a dust control valve, press the tip of the
valve to evacuate any accumulated dust particles. Check the air filter clogging indicator,
if the indicator is red, clean the air filter.
10. Keep the inlet opening open. Make sure that the generating set can easily take air
from the environment
11. Check the battery connection cables. Take care to tighten the loosened battery
terminals with spanner and, cover with special substance and keep clean in order to avoid
oxidation.
12. Check if the circuit breaker outlet switch is in OFF position. 13. Make sure that the
emergency stop button is not pressed.
4.2. Working principle
Working principle of diesel generator - A diesel generator is a device that produces
electricity by combining a diesel engine with a generator. This is a type of generator and
although most diesel compression ignition engines are designed to run on diesel fuel,
specific models are approved to run on other liquid fuels or natural gas. . Diesel generator
sets are used in places where there is no access to the grid as an emergency power source
if the grid fails and for more complex applications such as grid support, peak acceleration
and export to the power grid.

4.3. Generator control panel operation

To control and monitor the generating set, an (DEEP SEA ELECTRONICS PLC) has
been used. Control panel provides a means of starting and stopping the generating set,
monitoring its operation and output and automatically shutting down the set in the event
of critical condition arising such as low oil pressure or high engine temperature.
4.3.1. Push Buttons

4.3.2. Emergency stop

The generator is equipped with an emergency stop button which should only be used in
an emergency and not for general stopping.
4.4. Generating set control system
4.4.1. Manual Mode of Operation
This mode activated by pressing the MANUAL MODE pushbutton. A LED indicator
beside the button confirms this action. Press the button START to begin the start
sequence. After the fuel solenoid is energized, then the starter motor is engaged. The
engine is cranked for 10 sec. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for 10 sec. This sequence should continue beyond the 3
cranking attempts, the start sequence will be terminated and Fail to Start fault will be
displayed. When the engine fires, the starter motor is disengaged and locked out. Delayed
alarms (under speed, low oil pressure etc) will be monitored after the end of the Safety
On delay.
 The generator will continue to run on load regardless of the state of the mains supply. If
Auto mode is selected, and the mains supply is healthy then the Remote Stop Delay
Timer begins, after which the load is transferred to the mains. The generator will then run
off load allowing the engine a cooling down period. Selecting stop de-energizes the fuel
solenoid, bringing the generator to a stop.
4.4.2. Automatic Mode of operation
This mode is activated by pressing the AUTO MODE push button. A LED indicator
beside the button confirms this action. Should the mains (utility) supply fail outside the
configurable limits for longer than the period of the delay start timer, the mains healthy
indicator will extinguish . Additionally, while in AUTO mode, the remote start input is
monitored. Whether the start sequence is initiated by mains failure or by remote start
input, the following sequence is followed: To allow for short term mains supply transient
conditions or false remote start signals, the start delay timer is initiated. After the Fuel
Solenoid is energized, then 1 /2 second later, the starter motor is engaged. The engine is
cranked for 10 second. If the engine fails to fire during this cranking attempt than the
starter motor is disengaged for 10 second. Should this sequence continue beyond the 3
cranking attempts, the start sequence will be terminated and Fail to Start fault will be
displayed. When the engine fires, the starter motor is disengaged and locked out. Delayed
alarms (under speed, low oil pressure etc) will be monitored after the end of the Safety
On Delay. If the remote start is being used and has been configured to Remote Start is on
load, or the mains failed, the load will be transferred to the generator. On the return of the
mains supply, the Stop delay timer is initiated, once it has timed out, the load is
transferred back to the mains (utility). The cooling timer is than initiated, allowing the
engine a cooling down period (180 sec) off load before shutting down. Once the cooling
timer expires the fuel solenoid is de-energized, bringing the generator to a stop. Selecting
Stop de-energizes the fuel solenoid, bringing the generator to a stop.
4.4.3. Test Mode of Operation
This mode is activated by pressing the TEST MODE push button. A LED indicator
beside the button confirms this action. Press the START button to begin the test sequence.
After the Fuel Solenoidis energized, then 1/2 second later, the Starter Motor is engaged.
The engine is cranked for 10 second. If the engine fails to fire during this cranking
attempt then the starter motor is disengaged for 10 second. Should this sequence continue
beyond the 3 cranking attempts,the start sequence will be terminated and Fail to Start
fault will be displayed. When the engine fires, the starter motor is disengaged and locked
out. Delayed alarms (under speed, low oil pressure etc) will be monitored after the end of
the Safety On delay. The load will be transferred to the generator and the set will run on
load until Auto mode is selected or Stop is pressed. Selecting Stop de-energizes the fuel
solenoid, bringing the fuel solenoid, bringing the generator to a stop
4.5. Matters need attention
 Warnings are non-critical alarm conditions and do not affect the operation of the
generator system, they serve to draw the operators attention to an undesirable condition.
By default, warning alarms are self-resetting when the fault condition is removed. When
an alarm is active, the Common Alarm LED, illuminates and a message appears on the
module’s display. If configured, the external audible alarm also sounds. The external
audible alarm is silenced by pressing the Alarm Reset / Lamp Test button
The LCD display jumps from the ‘Information page’ to display the Alarm Page

V.
5.1. Troubleshooting of common failures
Reason of failure
1 diesel engine cannot be started properly
1 Low starting engine speed
1)Low battery capacity or loose connector
2) Poor contact between carbon brush of
starter and rectifier.
3)Starter teeth cannot be inserted into the
flywheel gear ring.
2 Abnormal fuel system
1)Empty fuel tank or valve of fuel tank is
closed.
2)Air in fuel system or water mixed in
fuel or fuel leakage for the connectors.
3)Fuel circuit blockage.
4)Fuel supply pump is not properly
Troubleshooting
1)Charging：tighten the connector
securely; repair the binding post if
necessary.
2)Repair or replace carbon brush.
3)Move the flywheel disk; check the
installation of starter if necessary to ensure
that starter is parallel to the axis line of
gear ring.
1)Refill：open the valve.
2)Discharge the air；change the diesel
fuel; tighten the connector securely.
3)Clean the pipelines；replace the
working.
5)Fuel injector is not working or giving a
poor performance with low torque and bad
atomization; broken pressure adjustment
spring of fuel injector; blockage of
injection hole.
6)Leakage of fuel outlet valve for fuel
injection pump; broken spring; abrasive
plunger and barrel assembly.
3 Poor compression pressure
1)Excessively large valve clearance.
2)Air leakage of valves.
3)Air leakage of cylinder head liner.
4)Piston ring is abrasive, gumming or
repeated in the opening.
4 Other reasons
1)Excessively low air temperature or large
oil viscosity.
2)Water mixed in the combustion chamber
or cylinders
Reason of failure
2. Abnormal oil pressure
Oil pressure is zero or too low
1 )Excessively low oil level, giving rise to
poor or thin oil quality.
2) Broken oil pipe;oil leakage due to loose
pipe joint; damaged oil pressure gauge.
3) Deformation or breakage of pressure
adjustment spring of oil pump
4) Excessively large clearance of oil
pump.
5) Broken oil pump gasket.
6) Excessively large clearance between
each bearing.
7) Plug screw of oil passage is loose and
element of fuel filter； clean the fuel inlet
pipe of fuel supply pump.
4)Check for any leakage of fuel inlet pipe
of fuel supply pump; check the fuel supply
pump.
5)Remove and check the fuel injector with
the tester; inspect the starting of fuel
injection pump.
6)Grinding: repair or replace spare parts.
1)Make adjustment as specified.
2)Grinding valve.
3)Replace cylinder head liner and screw
the bolt of cylinder head tightly as
specified.
4)Replacement, cleaning and adjustment.
1)Fill the cooling system with hot water;
preheat starting technology is
recommended; Use the designated oil
grade.
2)Inspection, repair, replacement
Troubleshooting
1_Oil filling；replace with new oil.
2_Welding; tighten it securely;
replacement.
3_Replacement.
4_Contact with factory to repair it;
replacement. 5_Replacement.
6_Inspection, adjustment or replacement.
7_Check for blockage.
leaked.
2 Oil pressure is too high 1_Inspection and adjustment.
1 ) Relief valve of oil pump is not
working properly, leading to poor oil 2_Use the designated oil grade and the oil
returning. viscosity will be naturally dropped after
2 )Large oil viscosity due to low warming.
temperature. 1_Clean and dredge
3 No oil reaching rocker arm shaft
1 ) Blockage of oil holes for oil passage of
upper cylinder head and at the bottom of
seat for rocker arm shaft.

Reason of failure Troubleshooting

3 Smoke in exhaust gas
Black smoke
1)Fuel injector is blocked by carbon 1) Inspection, repair and replacement.
deposit and needle valve is getting stuck.
2)Overload. 2) Adjust load to ensure it is within the
specified range.
3)Delay of fuel injection and some fuel is 3) Adjust the fuel supply advanced angle
burning during the process of emission. of fuel injection pump.
4)Incorrect valve clearance and poor 4) Check air valve clearance, contact of air
tightness of valve. valve sealing surface, performance of air
valve spring to eliminate any defect.
5) Uneven fuel supply of each cylinder for 5) Adjust fuel supply of each cylinder.
fuel injection pump.
6)Blockage of air intake pipe and air filter. 6) Remove and clean air filter.
2 White smoke
1) Low fuel injection pressure; poor 1) Inspect, adjust, repair or replace fuel
atomization with fuel drip. injector nozzle parts.
2) Low coolant temperature. 2) Increase coolant temperature.
3) 3Water getting into the cylinder. 3) Check cylinder head liner.
3 Blue smoke
1) Excessive abrasion of piston ring or oil 1) Clean or replace piston ring.
getting into the combustion chamber due
to bad elasticity as a result of carbon
deposit. 2) Discharge extra oil.
2) Oil level is too high. 3) Face the air ring marked with “upper”
3) Conical air rings are installed upside upwards.
dow
Reason of failure
4 Insufficient power
1 Blockage of fuel filter or filter of fuel
inlet pipe connector for fuel supply
pump.
2 Incorrect pressure or poor atomization
of fuel injector.
3 Excessively abrasion of precise parts
for fuel injection pump.
4 Deformation and loose of governor
spring, disabling the engine to reach
the rated speed.
5 Air mixed in the fuel system.
6 Incorrect fuel supply advanced angle.
7 Uneven fuel supply for each cylinder.
8 Blockage of air filter.
9 Air valve leakage.
10 Lack of compression pressure.
11 Wrong valve timing.
12 Leakage of fuel injector hole.
13 Loose cylinder head bolt.
Reason of failure
5 Abnormal noise
1 The fuel supply advanced angle is too
large and there are noises inside the
cylinder sound like knock on the
metal.
2 The fuel injection nozzle is dripping
oil and meshed with the needle valve,
causing noises sound like “da,da,da”.
Troublehooting
1 Clean or replacement.
2 Inspect fuel injector or replace fuel
injection nozzle parts.
3 Adjust fuel supply; check plunger
parts and fuel outlet valve part.
4 Adjust high-speed limit screw or
replace speed regulating spring.
5 Discharge air from the fuel system.
6 Adjust it as specified.
7 Adjust fuel supply for each cylinder.
8 Clean or replace filter element.
9 Check valve clearance, valve spring
performance, abrasion of valve tube,
sealing of valve and replace spare
parts or inspect valves if necessary.
10 Refer to section 1 and 3 of this
chapter.
11 Excessive abrasion of camshaft and
you may replace the camshaft.
12 Replace copper washer; clean the
surface of holes; tighten the nuts of
pressing plate evenly.
13 Tighten the bolts according to the
specified torque.
Troubleshooting
1Adjust the fuel supply advanced
angle.
2 Clean, repair or replace needle valve
parts.
3 Too large valve clearance will cause 3 Adjust the valve clearance.
clear and uniform knocking noise. 4 Increase the valve learance
4 The collision between piston and properly;correct the clearance for
valve will cause strong and uniform connecting rod bearing or replace the
knocking noise (You will feel connecting rod bearing shell
vibration of piston if putting your
hands slightly on the nuts of cylinder
head ).
5 Strong knocking noises can be head if 5 Replace the cylinder head liner.
piston is hitting the bottom of cylinder
head.
6 There will be slight knocking noises 6 Replace spring, push rod or tappet and
for the valve mechanism when valve adjust the valve clearance.
spring is broken, valve pushing rod is
bent or valve tappet is abrasive.
7 Noises because of the large clearance 7 Replace the cylinder liner and piston in
between piston and cylinder liner will line with the abrasion.
be relieved after the diesel engine is
warming up
8 In case of great clearance between 8 Replace the connecting rod bearing.
connecting rod bearing, strong knocking
noise can be heard when the speed is
abruptly dropped. 9 Replace the connecting rod liner.
9 Large clearance between connecting rod
liner and piston pin will result in slight
and sharp noise that can be especially 10 Replace the thrust plate of crankshaft
heard at idle speed.
10 If the thrust plate of crankshaft is
greatly worn with large clearance, the
noise caused by the knock of crankshaft at
idle speed can be heard.

Reason of failure Troubleshooting

6 Severe vibration
1 Uneven fuel supply for each cylinder;
some fuel injection nozzles have bad
atomization, severe gas leakage and
compression ratios of cylinders differ
greatly with each other.
2 Water and gas mixed in the diesel fuel.
1 Inspect and adjust fuel supply of fuel
injection pump; repair fuel injection
nozzle; eliminate leakage and check
the compression pressure for each
cylinder.
2 Discharge the air and make the diesel

3 The alignment is not proper for engine
installation and supporting bolts are
not tightly fixed.
4 Knocking noises heard from diesel
engine during operation.
7 Engine overheat
1 Fuel is getting into the crankcase; oil is
diluted with water; oil is insufficient or
excessive; the flow rate of oil is too small
with low pressure; the bearing clearance is
too small.
2 Water pump impeller is damaged or
cracked; fan belt is slippery; radiator and
fan are not installed in proper positions;
failure of thermostat; blockage
of cooling system; incrustation is greatly
built up in water jacket; insufficient
displacement of water
pump; lack of water; fuel gas is getting
into the water channel because of the
broken cylinder head liner.
8 Excessively large oil consumption
1 Use wrong oil grade with low oil
viscosity.
2 Great abrasion between piston and
cylinder liner; blockage of oil returning
hole for piston ring groove.
3 Piston ring is glued; F-side of air ring is
installed inversely with much abrasion.
4 Oil leakage discovered for the front and
rear oil seal of crankshaft, connecting
surface of oil pan and side cover seals.
5 The oil temperature and pressure is
too high
Reason of failure
9 Sharbly increase of engine speed
1 Governor is failed; pull rod is getting
fuel precipitate.
3 Check the alignment and tighten the
bolt securely.
4 Check the fuel supply advanced angle
and apply the load after the diesel
engine is warmed up.
1 Inspect and replace piston ring;
replace the oil; check the oil level;
check the abrasion of outer rotor
inside the oil pump; check the
clearance between the bearings.
2 Check and replace water pump
impeller; Check the tension of fan belt
or replace the belt; check the
installation position of radiator; check
the performance of thermostat; clean
the cooling system and water jacket;
check the clearance of water pump
impeller; refill the water; replace
cylinder head liner.
1 Change to the designated oil grade.
2 Replace and clean the oil returning
hole.
3 Clean or replace.
4 Check or replace relevant spare parts.
5. Reduce the temperature(Refer to the
last section); check and adjust the
relief valve of oil pump.
Troubleshooting
1 Repair governor and its pull rod.
 stuck at the position of high fuel level.
2Sliding disk sleeve of governor is getting 2 Repair it.
stuck. 3 Repair it.
3 Adjusting arm is removed from fork.
10 Shut-down by itself
1 Air mixed in fuel pipeline; failure of 1 Discharge air and repair the fuel supply
fuel supply pump; blockage of fuel filter. pump; clean the diesel filter.
2 Piston seizing; shaft neck is completely 2 Since the clearance is not correct, repair
seized by bearing bush. and replace it.
3 Fuel outlet valve of fuel injection pump 3 Repair or replace it.
is getting stuck; broken of plunger spring;
Sliding disk sleeve of governor is getting
stuck.
11 Engine speed fluctuated with in a certain range
1 Uneven fuel supply for each cylinder; 1 Make the adjustment and ensure the
fuel drip of fuel injector; fork screws of even fuel supply for each cylinder;
pull rod are loose. repair or replace the needle valve parts
for fuel injection nozzle; fix the fork
screw.
2 Replace spare parts.
2 Clearance between fork and adjusting
arm is too large; sink mark appears as the
result of abrasion between steel ball and 3 Adjust with copper washer.
sliding plate.
3 The axial movement of fuel injection 4 Clean, repair or replace the sleeve.
pump and camshaft is too large.
4 Sliding disk sleeve is getting stuck

Troubleshooting of common failures

Reason of failure
1 diesel engine cannot be started properly
1 Low starting engine speed
1)Low battery capacity or loose connector
2) Poor contact between carbon brush of
starter and rectifier.
3)Starter teeth cannot be inserted into the
flywheel gear ring.
2 Abnormal fuel system
1)Empty fuel tank or valve of fuel tank is
closed.
Troubleshooting
1)Charging：tighten the connector
securely; repair the binding post if
necessary.
2)Repair or replace carbon brush.
3)Move the flywheel disk; check the
installation of starter if necessary to ensure
that starter is parallel to the axis line of
gear ring.
2)Air in fuel system or water mixed in
fuel or fuel leakage for the connectors.
3)Fuel circuit blockage.
4)Fuel supply pump is not properly
working.
5)Fuel injector is not working or giving a
poor performance with low torque and bad
atomization; broken pressure adjustment
spring of fuel injector; blockage of
injection hole.
6)Leakage of fuel outlet valve for fuel
injection pump; broken spring; abrasive
plunger and barrel assembly.
3 Poor compression pressure
1)Excessively large valve clearance.
2)Air leakage of valves.
3)Air leakage of cylinder head liner.
4)Piston ring is abrasive, gumming or
repeated in the opening.
4 Other reasons
1)Excessively low air temperature or large
oil viscosity.
2)Water mixed in the combustion chamber
or cylinders
Reason of failure
2. Abnormal oil pressure
Oil pressure is zero or too low
1 )Excessively low oil level, giving rise to
poor or thin oil quality.
2) Broken oil pipe;oil leakage due to loose
pipe joint; damaged oil pressure gauge.
3) Deformation or breakage of pressure
adjustment spring of oil pump
4) Excessively large clearance of oil
pump.
1)Refill：open the valve.
2)Discharge the air；change the diesel
fuel; tighten the connector securely.
3)Clean the pipelines；replace the
element of fuel filter； clean the fuel inlet
pipe of fuel supply pump.
4)Check for any leakage of fuel inlet pipe
of fuel supply pump; check the fuel supply
pump.
5)Remove and check the fuel injector with
the tester; inspect the starting of fuel
injection pump.
6)Grinding: repair or replace spare parts.
1)Make adjustment as specified.
2)Grinding valve.
3)Replace cylinder head liner and screw
the bolt of cylinder head tightly as
specified.
4)Replacement, cleaning and adjustment.
1)Fill the cooling system with hot water;
preheat starting technology is
recommended; Use the designated oil
grade.
2)Inspection, repair, replacement
Troubleshooting
1_Oil filling；replace with new oil.
2_Welding; tighten it securely;
replacement.
3_Replacement.
4_Contact with factory to repair it;
5) Broken oil pump gasket. replacement. 5_Replacement.
6) Excessively large clearance between 6_Inspection, adjustment or replacement.
each bearing.
7) Plug screw of oil passage is loose and 7_Check for blockage.
leaked.
2 Oil pressure is too high 1_Inspection and adjustment.
1 ) Relief valve of oil pump is not
working properly, leading to poor oil 2_Use the designated oil grade and the oil
returning. viscosity will be naturally dropped after
2 )Large oil viscosity due to low warming.
temperature. 1_Clean and dredge
3 No oil reaching rocker arm shaft
1 ) Blockage of oil holes for oil passage of
upper cylinder head and at the bottom of
seat for rocker arm shaft.

Reason of failure Troubleshooting

3 Smoke in exhaust gas
Black smoke
1)Fuel injector is blocked by carbon 1) Inspection, repair and replacement.
deposit and needle valve is getting stuck.
2)Overload. 2) Adjust load to ensure it is within the
specified range.
3)Delay of fuel injection and some fuel is 3) Adjust the fuel supply advanced angle
burning during the process of emission. of fuel injection pump.
4)Incorrect valve clearance and poor 4) Check air valve clearance, contact of air
tightness of valve. valve sealing surface, performance of air
valve spring to eliminate any defect.
5) Uneven fuel supply of each cylinder for 5) Adjust fuel supply of each cylinder.
fuel injection pump.
6)Blockage of air intake pipe and air filter. 6) Remove and clean air filter.
2 White smoke
1) Low fuel injection pressure; poor 1) Inspect, adjust, repair or replace fuel
atomization with fuel drip. injector nozzle parts.
2) Low coolant temperature. 2) Increase coolant temperature.
3) 3Water getting into the cylinder. 3) Check cylinder head liner.
3 Blue smoke
1) Excessive abrasion of piston ring or oil 1) Clean or replace piston ring.
getting into the combustion chamber due
to bad elasticity as a result of carbon
deposit. 2) Discharge extra oil.
2) Oil level is too high. 3) Face the air ring marked with “upper”
3) Conical air rings are installed upside
dow
Reason of failure
4 Insufficient power
1 Blockage of fuel filter or filter of fuel
inlet pipe connector for fuel supply
pump.
2 Incorrect pressure or poor atomization
of fuel injector.
3 Excessively abrasion of precise parts
for fuel injection pump.
4 Deformation and loose of governor
spring, disabling the engine to reach
the rated speed.
5 Air mixed in the fuel system.
6 Incorrect fuel supply advanced angle.
7 Uneven fuel supply for each cylinder.
8 Blockage of air filter.
9 Air valve leakage.
10 Lack of compression pressure.
11 Wrong valve timing.
12 Leakage of fuel injector hole.
13 Loose cylinder head bolt.
Reason of failure
5 Abnormal noise
1 The fuel supply advanced angle is too
large and there are noises inside the
cylinder sound like knock on the
upwards.
Troublehooting
1 Clean or replacement.
2 Inspect fuel injector or replace fuel
injection nozzle parts.
3 Adjust fuel supply; check plunger
parts and fuel outlet valve part.
4 Adjust high-speed limit screw or
replace speed regulating spring.
5 Discharge air from the fuel system.
6 Adjust it as specified.
7 Adjust fuel supply for each cylinder.
8 Clean or replace filter element.
9 Check valve clearance, valve spring
performance, abrasion of valve tube,
sealing of valve and replace spare
parts or inspect valves if necessary.
10 Refer to section 1 and 3 of this
chapter.
11 Excessive abrasion of camshaft and
you may replace the camshaft.
12 Replace copper washer; clean the
surface of holes; tighten the nuts of
pressing plate evenly.
13 Tighten the bolts according to the
specified torque.
Troubleshooting
1Adjust the fuel supply advanced
angle.
metal.
2 The fuel injection nozzle is dripping 2 Clean, repair or replace needle valve
oil and meshed with the needle valve, parts.
causing noises sound like “da,da,da”.
3 Too large valve clearance will cause 3 Adjust the valve clearance.
clear and uniform knocking noise. 4 Increase the valve learance
4 The collision between piston and properly;correct the clearance for
valve will cause strong and uniform connecting rod bearing or replace the
knocking noise (You will feel connecting rod bearing shell
vibration of piston if putting your
hands slightly on the nuts of cylinder
head ).
5 Strong knocking noises can be head if 5 Replace the cylinder head liner.
piston is hitting the bottom of cylinder
head.
6 There will be slight knocking noises 6 Replace spring, push rod or tappet and
for the valve mechanism when valve adjust the valve clearance.
spring is broken, valve pushing rod is
bent or valve tappet is abrasive.
7 Noises because of the large clearance 7 Replace the cylinder liner and piston in
between piston and cylinder liner will line with the abrasion.
be relieved after the diesel engine is
warming up
8 In case of great clearance between 8 Replace the connecting rod bearing.
connecting rod bearing, strong knocking
noise can be heard when the speed is
abruptly dropped. 9 Replace the connecting rod liner.
9 Large clearance between connecting rod
liner and piston pin will result in slight
and sharp noise that can be especially 10 Replace the thrust plate of crankshaft
heard at idle speed.
10 If the thrust plate of crankshaft is
greatly worn with large clearance, the
noise caused by the knock of crankshaft at
idle speed can be heard.

Reason of failure Troubleshooting

6 Severe vibration
1 Uneven fuel supply for each cylinder; 1 Inspect and adjust fuel supply of fuel
some fuel injection nozzles have bad injection pump; repair fuel injection
atomization, severe gas leakage and
compression ratios of cylinders differ
greatly with each other.
2 Water and gas mixed in the diesel fuel.
3 The alignment is not proper for engine
installation and supporting bolts are
not tightly fixed.
4 Knocking noises heard from diesel
engine during operation.
7 Engine overheat
1 Fuel is getting into the crankcase; oil is
diluted with water; oil is insufficient or
excessive; the flow rate of oil is too small
with low pressure; the bearing clearance is
too small.
2 Water pump impeller is damaged or
cracked; fan belt is slippery; radiator and
fan are not installed in proper positions;
failure of thermostat; blockage
of cooling system; incrustation is greatly
built up in water jacket; insufficient
displacement of water
pump; lack of water; fuel gas is getting
into the water channel because of the
broken cylinder head liner.
8 Excessively large oil consumption
1 Use wrong oil grade with low oil
viscosity.
2 Great abrasion between piston and
cylinder liner; blockage of oil returning
hole for piston ring groove.
3 Piston ring is glued; F-side of air ring is
installed inversely with much abrasion.
4 Oil leakage discovered for the front and
rear oil seal of crankshaft, connecting
surface of oil pan and side cover seals.
5 The oil temperature and pressure is
too high
nozzle; eliminate leakage and check
the compression pressure for each
cylinder.
2 Discharge the air and make the diesel
fuel precipitate.
3 Check the alignment and tighten the
bolt securely.
4 Check the fuel supply advanced angle
and apply the load after the diesel
engine is warmed up.
1 Inspect and replace piston ring;
replace the oil; check the oil level;
check the abrasion of outer rotor
inside the oil pump; check the
clearance between the bearings.
2 Check and replace water pump
impeller; Check the tension of fan belt
or replace the belt; check the
installation position of radiator; check
the performance of thermostat; clean
the cooling system and water jacket;
check the clearance of water pump
impeller; refill the water; replace
cylinder head liner.
1 Change to the designated oil grade.
2 Replace and clean the oil returning
hole.
3 Clean or replace.
4 Check or replace relevant spare parts.
5. Reduce the temperature(Refer to the
last section); check and adjust the
relief valve of oil pump.
Reason of failure Troubleshooting
9 Sharbly increase of engine speed
1 Governor is failed; pull rod is getting 1 Repair governor and its pull rod.
stuck at the position of high fuel level.
2Sliding disk sleeve of governor is getting 2 Repair it.
stuck. 3 Repair it.
3 Adjusting arm is removed from fork.
10 Shut-down by itself
1 Air mixed in fuel pipeline; failure of 1 Discharge air and repair the fuel supply
fuel supply pump; blockage of fuel filter. pump; clean the diesel filter.
2 Piston seizing; shaft neck is completely 2 Since the clearance is not correct, repair
seized by bearing bush. and replace it.
3 Fuel outlet valve of fuel injection pump 3 Repair or replace it.
is getting stuck; broken of plunger spring;
Sliding disk sleeve of governor is getting
stuck.
11 Engine speed fluctuated with in a certain range
1 Uneven fuel supply for each cylinder; 1 Make the adjustment and ensure the
fuel drip of fuel injector; fork screws of even fuel supply for each cylinder;
pull rod are loose. repair or replace the needle valve parts
for fuel injection nozzle; fix the fork
screw.
2 Replace spare parts.
2 Clearance between fork and adjusting
arm is too large; sink mark appears as the
result of abrasion between steel ball and 3 Adjust with copper washer.
sliding plate.
3 The axial movement of fuel injection 4 Clean, repair or replace the sleeve.
pump and camshaft is too large.
4 Sliding disk sleeve is getting stuck