500kVA Generator Starting Problem

You would best have name brand and manufacturer of said generator and while you are at it tell us what their customer support said to avoid guess work on our part.

When the generator stopped to start did it start and then stop or started to a stop?

Was it not rather the engine driving the generator that did not start?

How does the electrical side of the generator look like?

What has the manual to say about this?

If in doubt call the manufacturer.

I dont think the nozzles are the problem. Its something else.

The name of the generator is Caterpillar serial number CAT00000H8A201447, 500kVA, 400kW

Engine model 3406E, 435kW at 1500rpm.

Customer support said the problem is nozzles. However, we think the problem might be something else as it is normal for all 6 nozzles to fail at the same time. That is why we are trying to find out what might be the problem.

The engine did not start when trying to start in the morning, the starter is ok, and there is no problem on the generator side.

Electrical side of the generator is OK

We currently don't have the manual, trying to look for it.

Regards

D.D.Mtonyole

Finding the manual would prove valuable.

http://www.truckmanuals.com/index.php?l=product_list&c=62

Not sure you would have to pay for it. But it might be so.

Here is a must have document.

Dear Mr.dmtonyole,

The reasons are many for the DG set not starting. They are as follows.

1. Battery does not have sufficient strength to crank the Engine. Pl. check the Battery strength.

2. Engine Compression may be much less than the minimum requires. This is very essential to ignite the fuel and develope combustion of fuel.

3. The fuel may not be pure and adultred, and may not develope power to sustain normal running.

4. Fuel Injection may not be proper at the desired pressure to maintain the degree of atomisation.

5. Piston Rings might have broken and leakage of compressed air is possible.

6. Turbo-Charger may not supply the required air in-take. Check the Turbo-Charger.

7. Air Filter at the Turb-Charger might have been blocked - preventing proper suction of air. Pl. check for this.

8. Similarly required quantity of fuel is not pumped to maintain combustion in a sustained manner.

9. Valve Timings for opening and closing of Inlet and Outlet might have been disturbed. Pl. check for this.

10. The Fuel Injection timing might have been disturbed. This should be slightly before the end of the compression stroke and should not continue during power stroke.

11. The cam profile might have been worn out abnormally and the relative angular position might have been disturbed.

12. The gear driving the cam shaft might have been severely worn out. Pl. check for the same.

The above is on the mechanical aspect of the problem and there could be some problem on the generator side also. Pl. check for the same.

Inform this forum how the problem was solved.

DHAYANANDHAN.S

Dear all

Problem of the generator not starting has been rectified.

The problem was on the nozzles, specifically the actuators was damaged and not functioning properly. All six actuators has been replaced and nozzles installed back to the generator. Currently, the generator is starting properly and it is in good working condition.

Regards

D.D.Mtonyole

Any idea how all six were damaged simultaneously?

There are way too many things that could be wrong.

Call Cat and get a trained and certified repairman on the job!

Dear dmtonyole,

I want to know the duration of trial that u must be taking for Generator. Because this type of problem comes mostly due to Battery is not charged or battery is not functioning properly as Mr. DHAYANANDHAN.S written. So, it may be due to what the engine is not taking required ignition. Also check the fuel supply. Sometimes it may happen that due to air blockage in the fuel supply line the engine is not getting proper required fuel if engine is starting and then stops immediately or even if it not starts.

Regards,

Nishant

So ECM doesn't tell the injector pump fuel solenoid to open the fuel but the solenoid does snap open with an external DC source.

Have you tried cranking it to determine if it starts in this condition? (lock out the ATS, if equipped, first).

Diesels need several things to start.. Good mechanical condition is assumed. Diesel needs air, fuel and compression via motion. If it cranks over crack several injection lines if it used this system and see if fuel flows. Diesels have a reputation for plugged exhaust and this usually is displayed by firing but not continuing to run or run poorly. If this is an electronic injected engine then read the manual but before you start reading call the factory rep. By the time the rep arrives you will have advanced your learning, possibly.