Mecca Power, as part of a Global Power Supplier initiative, provides a professional solution for the design, application and after-sales support of generators.
Strongly focused on innovation and the inherent flexibility of product design, Mecca Power has been successful in global markets with a broad and diverse range of genset power products that can operate autonomously or independently. parallel, on-site or remotely controlled.
With more than 10 years of experience in manufacturing and exporting energy products, as well as our sales and engineering group in the United States, the Mecca team will advise you on product choices.
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General Troubleshooting
This section lists the generating set for some common fault, the reasons for the failure and determines the
method of fault. General operators can determine their own fault and note, maintenance it according to the
brochure. But please contact the repairing agents when meeting a special note or not listed failure of operation.
Please remember the following suggestions before repairing:
- Make sure that study the failure carefully before any operation.
- Repair with the easiest way and most commonly used method.
- Find the exact causes of failure and completely solve the fault.
1. Generator Sets
Description of this section is for reference only. If the following failure occurs please contact the repairing agents.
(Some models of control panel installed only parts of the following warning indicator light)
| Icon |
Indicator Light |
Reason |
Fault Analysis |
Low oil pressure
alarm |
Low oil pressure
alarm |
When oil pressure does not
reduce normally, the light is on. |
-General because of a lack of oil or lubrication
system failure caused by (refueling or replacing
the oil filter)
-When occurs this fault should automatically
shutdown generator sets immediately. |
High water
temperature
alarm |
High water
temperature
alarm |
When the water temperature
has risen to a level higher than
or equal to the sensor setting,
the light is on. |
-General because of a lack of water or oil
shortage, or overload.
-When occurs this fault should automatically
shutdown generator sets immediately. |
Low fuel level
alarm |
Low fuel level
alarm |
When a fuel level has been
detected by the sensor fitted to
the daily tank, the light is on. |
-General because of a lack of water or oil
shortage, or overload.
-When occurs this fault should automatically
shutdown generator sets immediately. |
Battery charger
fault alarm |
Battery charger
fault alarm |
If the charging system has fault,
when engine running, the light is
off. |
-Battery charging system fault caused.
-The light is on at the initial start, when the
charger reaches a certain speed, the light is off.
-This failure will not lead to automatic shutdown
generating units. |
Crank failure
alarm |
Crank failure
alarm |
When the generator set failed
three times (or six times) in a
row starting, the light is on. |
-Oil supply system or re-start the system failure
caused. |
Overload or
breaker tripping
alarm |
Overload or
breaker tripping
alarm |
When overloading or Short
circuit, the light is on. Tripping
circuit breakers cause generator
set load out. |
-In this fault, it need to load or unload some parts
to eliminate short-circuit, and then re-close the
circuit breaker. |
Introduction of Maintenance grade(Interval) for the generator set
A Level Maintenance Interval (Daily Maintenance)
1. Check Daily Report of Genset .
2. Check fuel level and coolant level.
3. Check alternator for cracks or other damage, and the condition of the belts must be checked, flab or
other damage.
4. Check the Air filter. The air filter should be replaced when necessary .
5. Release fuel tank and fuel filter's water and sediment.
6. Check the water cooling filter.
7. Check starting battery and electrolyte, add electrolyte when necessary.
8. Check the starter, check noisy defect.
9. Use air syringe cleaner to clean the water tank, coolant system and cooled fin net.
B Level Maintenance Interval (Less than 400 hours)
1. Repeatedly check A Level Daily Maintenance steps.
2. After operating 100 to 250 hours, replace the fuel filter. All the fuel filters should not be cleaned, it
should be replaced. 100 to 250 hours is just flexible time, actually it must be according to the practice
and real fact.
3. After operating 200 to 250 hours, replace the oil & oil filter. All the lube oil must fit up to the CF
Grade of American Petroleum Institute.
4. After operating 300 to 400 hours, replace the air filter. The air filter can be cleaned with air syringe, or
it can be replaced. The replacement must be according to the environment and real fact.
5. Replace the cooling system and add coolant concentration.
6. Clean the crankshaft and inlet, outlet air- filter net.
C Level Maintenance Interval (2000-3000 hours), Please do as follows:
1. Repeatedly check A and B Level Daily Maintenance steps.
2. Remove the tap of valve, clean and wash oil dirt and sludge.
3. Fasten snails from each part (including running parts and fixed parts)
4. Clean and wash the crankcase, oil sludge, steel scraps and sediment with engine.
5. Check wearing of the engine turbo, clean and wash accumulation of carbon, adjust it when necessary.
6. Check and adjust valve clearance.
7. Check PT pump, quality of injection, adjust injection process, adjust it when necessary.
8. Check and adjust the tension of fan belt and water pump belt, adjust and replace it when necessary;
clean and wash water tank radiator fins, then check the using capability of thermostat.
Current Repair (D Level Maintenance)(3000-4000 hours)
1. Check valve, valve seat and other wearing, repair or change it when necessary.
2. Check P pump, quality of injection, repair and adjust it when necessary.
3. Check and adjust connecting rod and fastening twisting torque.
4. Check and adjust valve clearance.
5. Check the trip of injector.
6. Check and adjust tension of fan and generating belt.
7. Clean and wash accumulation of carbon in inlet pipes.
8. Clean and wash the core of air cooler.
9. Clean and wash the whole oil lubrication system.
10. Clean and wash room of rocker arm, oil sludge in the sump and Metal scrap-iron.
Medium Repair (6000-8000 hours)
1. Including the items of minor repair.
2. Disassemble generator(except crankshaft)
3. Check the easy worn spare parts in pitman shaft system, gas distribution system, lubrication system,
cooling system of cylinder, Piston, Intake and exhaust valve, replace them when necessary.
4. Check fuel supplying system, adjust oil pump and injector.
5. Repair and test the alternator, clean oil-sediment and lubricate the bearing of alternator.
Overhaul (9000-15000hours)
1. Including the items of intermediate repair.
2. Disassemble all the parts in the generator.
3. Replace cylinder, piston, piston loop, big and small bearing bushes, trusting pad of crankshaft, intake
and exhaust valve, a whole set of tools for generator repair
4. Adjust oil pump, injector and replace pump core, injector
5. Replace a whole set of repair tools for turbo charger and a repair set for water pump.
6. Adjust the parts of connecting rod, crankshaft and generator body,repair or replace them when necessary
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