OPERATOR TROUBLESHOOTING PROCEDURES FOR
GENSET (ENGINE) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Personnel Required References
Two WP 0005, WP 0006, WP 0022, WP 0023
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by operator-level qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of the TMSS- MED. Each section is arranged according to the condition/indication of a problem. The corrective action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot identify all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer, ensure hand brakes are engaged and wheels are chocked. Injury to personnel could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all switches and circuit breakers have been de-energized prior to performing any procedures.
Voltage sources, in addition to being an electrical shock hazard, may also potentially produce serious burns. Care should be exercised when using hand tools around exposed power connectors, never letting the tool bridge two terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT attempt to energize repeatedly. That could create an overload situation hazardous to
personnel and equipment. Instead, investigate and identify cause of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry before working around TMSS-MED. Jewelry can catch on equipment and cause injury or may short across and electrical circuit and cause severe burns or electrical shock If Genset has been in operation, fluids and components may be extremely hot. To prevent serious injury to personnel, allow the Genset to cool down before performing procedures.
Part Number 1006313 0012-2 DHS Systems LLC
This document contains information proprietary to DHS Systems LLC and is intended solely for use by its customers. No portion of this document may be reproduced release to a third party without written consent of DHS Systems LLC.
Table 1. Operator Troubleshooting – Genset (Engine).
ITEM CONDITION/INDICATION CORRECTIVE ACTION
WARNING
If Genset has been in operation, components (i.e., engine, radiator) may be extremely hot. To prevent serious injury to personnel, allow sufficient time for cool down before proceeding with checks.
1 Coolant leaking Inspect overflow bottle and hose for damage or leaking. Inspect radiator for damage or leaking.
Inspect coolant hoses for proper connections, damage, leaking.
Check coolant drain valves are turned off and drain plug is secure.
Contact Service Maintenance.
2 Fuel leaking WARNING
All fuels generate explosive fumes and gases. Utilize extreme caution. Do not smoke or use open flame when in the vicinity of fuels and associated tanks, lines. Death or severe burns to the operator or damage to the equipment may result.
Inspect fuel tank for damage or leaking. Inspect fuel lines for damage or leaking. Inspect fuel pump for damage or leaking. Inspect fuel filter for damage or leaking.
Check fuel drain valve is turned off and drain plug is secure.
Contact Service Maintenance.
3 Oil leaking Inspect oil filter for damage or leaking.
Inspect oil pan for damage or leaking. Inspect oil lines and drain valves. Contact Service Maintenance.
Part Number 1006313 0012-3 DHS Systems LLC
This document contains information proprietary to DHS Systems LLC and is intended solely for use by its customers. No portion of this document may be reproduced release to a third party without written consent of DHS Systems LLC.
Table 1. Operator Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
4 Battery acid leaking WARNING
Batteries generate explosive gas during charging. Utilize extreme caution. Do not smoke or use open flame in the vicinity of the battery. Death or severe burns may result.
Battery acid can be dangerous, do not touch. Death or severe burns may result.
Inspect battery for cracks or other brakes. Contact Service Maintenance.
5 Engine does not crank Check BATTERY SWITCH is set to ON. Check batteries for loose connections.
Check for loose ground connection on engine. Check solenoid(s) and starter for loose connections. Check for low voltage. If below 24 VDC, attach generator NATO slave receptacle to vehicle and attempt to start engine (WP 0005).
Contact Service Maintenance.
6 Engine turns over slowly Attach generator NATO slave receptacle to vehicle or trailer and attempt to start engine (WP 0005). If engine still starts slowly, contact Service Maintenance.
7 Engine cranks but does not start Check if EMERGENCY STOP button pushed in. Reset. Check for fuel supply valve set to proper operating mode (WP 0005). Reset.
Check actuator and diesel speed sensor connections. Check for fuel.
Check fuel level in fuel tank. Add fuel and restart engine (WP 0005).
Contact Service Maintenance. 8 Engine cranks but does not start (ambient
temperature below 32°F (0°C))
Check if EMERGENCY STOP button pushed in. Reset. Check for fuel supply valve is set to proper operating mode (WP 0005). Reset.
Part Number 1006313 0012-4 DHS Systems LLC
This document contains information proprietary to DHS Systems LLC and is intended solely for use by its customers. No portion of this document may be reproduced release to a third party without written consent of DHS Systems LLC.
Table 1. Operator Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
8 (cont.)
Set ENGINE switch to PREHEAT for approximately 30 seconds. Restart.
Check fuel level in fuel tank. Add fuel and restart engine (WP 0005).
Set ENGINE HEATER (hydronic) and FUEL LINE HEATER switches to on (UP) (WP 0006).
Contact Service Maintenance.
9 Engine stops (no warning lights) Check if EMERGENCY STOP button pushed in. Reset. No fuel. Refill fuel tank, Set CB1 – CB5 OFF and remove load. Turn ENGINE switch to OFF then to START to restart engine (WP 0005).
Contact Service Maintenance 10 Engine stops (HIGH COOLANT TEMP
warning light on)
WARNING
If coolant is not visible in radiator, let the engine cool down then restart engine and add coolant while the engine is running.
Engine overheating due to lack of coolant. Refill radiator to 1" and overflow bottle to proper level of 1/3 to 1/2 full. (WP 0022)
Turn ENGINE switch to OFF then to START to restart engine and check warning light (WP 0005).
Re-circulated exhaust gas or engine air. Reposition trailer for better circulation. Turn ENGINE switch to OFF then to START to restart engine and check warning light (WP 0005)
Obstructed air inlets or exhausts. Clear air inlets and exhausts. Turn ENGINE switch to OFF then to START to restart engine and check warning light (WP 0005). Overloaded engine. Reduce load on engine. Turn ENGINE switch to OFF then to START to restart engine and check warning light (WP 0005)
Contact Service Maintenance. 11 Engine stops (LOW OIL PRESSURE
warning light on)
Engine shutdown due to low oil pressure. Check and refill engine oil (WP 0022). Turn ENGINE switch to START to restart engine. Check warning light (WP 0005).
Part Number 1006313 0012-5 DHS Systems LLC
This document contains information proprietary to DHS Systems LLC and is intended solely for use by its customers. No portion of this document may be reproduced release to a third party without written consent of DHS Systems LLC.
Table 1. Operator Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
12 Engine stops (OVERSPEED warning light on)
Check for fuel. Refill fuel tank. Turn ENGINE switch to OFF then to START to restart engine (WP 0005). Contact Service Maintenance.
13 Excessive carbon deposits appear on exhaust outlet
WARNING
If Genset has been in operation, exhaust system (pipes, muffler, spark arrestor) may be extremely hot. To prevent serious injury to personnel, allow sufficient time for cool down before proceeding.
Engine operating without sufficient load. Perform the following:
• Add additional load to the engine by turning on the ECU and operating at minimum 50% load for 4 hours. Obstructed exhaust system. Perform the following:
• Check that exhaust pipe outlet is not clogged or blocked.
• Check that an exhaust pipe is not broken. • Check rain cap for proper function.
Obstructed air inlet system. Perform the following: • Check that air filter inlet is not blocked. • Check that air filter is not clogged.
Contaminated fuel. Contact Service Maintenance. Contact Service Maintenance.
14 Engine emits excessive smoke Ensure FUEL SUPPLY switch is placed fully in proper position.
Contact Service Maintenance. 15 DC VOLT Meter reads below 28 VDC
while Genset is running
Contact Service Maintenance.
16 Engine temperature remains below 120°F (48.88°C)
Contact Service Maintenance.
17 AC KILOWATTS meter reads 0 with Genset under load
Contact Service Maintenance.
18 Engine temperature above 220°F on COOLANT TEMP gauge (104.4°C), engine still running
NOTE
At high ambient temperatures the COOLANT TEMP gauge temp can read 230° F (110°C) normally.
Part Number 1006313 0012-6 DHS Systems LLC
This document contains information proprietary to DHS Systems LLC and is intended solely for use by its customers. No portion of this document may be reproduced release to a third party without written consent of DHS Systems LLC.
Table 1. Operator Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
18 (cont.)
Engine temperature above 220°F on COOLANT TEMP gauge (104.4°C), engine still running
Shut down system (WP 0005). Contact Service Maintenance.
19 Engine oil pressure below 20 psi, engine still running
NOTE
At high ambient temperatures the OIL PRESSURE gauge temp can read 15 psi normally.
Shut down system (WP 0005). Contact Service Maintenance.
NOTE
When ENGINE HEATER switch (on Genset control panel) flashes, there is a problem with the engine heater (hydronic). See Table 2 for fault codes.
20 Engine heater (hydronic) will not start (no fault code)
Check batteries are connected. Check battery switch is turned to on.
Check battery voltage is above 20 VDC. If low, recharge batteries (WP 0023) or slave off vehicle.
Contact Service Maintenance. 21 Engine heater (hydronic) (fault code F01
or F02)
Turn ENGINE HEATER switch on Genset control panel off for 2 minutes.
Check Genset fuel level, fuel Genset if necessary (WP 0005).
Contact Service Maintenance.
22 Engine heater (hydronic) (fault code F03) Turn ENGINE HEATER switch on Genset control panel off for 2 minutes.
Check battery voltage on DC VOLTS meter. If low, recharge batteries (WP 0023) or slave off vehicle. If voltage within 22 to 28 VDC, contact Service Maintenance.
Turn ENGINE HEATER switch on Genset control panel ON.
Contact Service Maintenance. 23 Engine heater (hydronic) (fault code F04,
F05, F06, F07, F08, F09, F010)
Part Number 1006313 0012-7/8 blank DHS Systems LLC
This document contains information proprietary to DHS Systems LLC and is intended solely for use by its customers. No portion of this document may be reproduced release to a third party without written consent of DHS Systems LLC.
NOTE
When ENGINE HEATER switch (on Genset control panel) flashes, there is a problem with the Engine heater (Hydronic). The number of flashes indicates a specific fault code (i.e., one flash is F01, two flashes is F02).
There is a sequence of slow and fast flashes. Count the slow flashes. Table 2. Engine Heater (Hydronic) Fault Codes. FAULT
CODE DESCRIPTION POSSIBLE CAUSE
F01 No Start-up • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust.
F02 Flame Extinguished • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust.
F03 Under/Over voltage • Vehicle Charging System.
F04 Premature Flame Detection • Heater faulty
F05 Circulating Pump Interruption or Short Circuit • Open or Shorted Wiring • Defective Pump F06 Temperature Sensor Interruption or Short Circuit • Heater faulty F07 Metering Pump (Fuel pump) Interruption or Short
Circuit
• Open or Shorted Wiring
F08 Combustion Fan Motor Interruption, Short Circuit or Incorrect fan Speed
• Heater faulty
F09 Pencil Type Glow Plug/Flame Detector Interruption or Short Circuit
• Heater faulty
F10 Overheating Condition • Coolant Flow Restriction
• Circulation Pump