Customer Care

Customer Care Numbers

Kirloskar and Genlite offer you a double layer of after-sales care and service. For your care needs, you can call the following customer numbers:

Kirloskar	1800-233-3344 (Toll-free from BSNL, MTNL) 020-6608-4608 (other than BSNL, MTNL)
Genlite	044-4231-7766, 044-2527-0985

Advice on Routine Checks and Troubleshooting for Gensets

We provide here basic tips on two important areas – routine checks you can perform and the troubleshooting measures you can perform yourself.

Routine Check Points

Lube Oil: Be sure to check the oil level before each operation.

Air Cleaner: Check air cleaner periodically in accordance with the Engine's operation manual.

Leakage: Check for oil and coolant leakage. Attend and rectify immediately, if any.

Radiator: Check coolant level after it becomes cool. Do not remove the cap except for K cool replenishment.

Battery: Check the Electrolyte level in the Battery and replenish some distilled water if low.

Loose Connection: Check cables, wires, nuts, bolts, etc periodically.

Power

1. Check appropriate load.
2. Ensure proper earthing.
3. Do not use start key when set is running.

DOs

1. Refer Maintenance chart for initial starting.
2. Keep DG set clean.
3. Use "K" oil.4. Ensure and correct
battery polarity.
5. Keep all Bolt/Nuts tight.
6. Keep battery on stand only.
7. Run DG set for 10 minutes after removing load before stopping.

DON'Ts

1. Do not open door while DG set is running.
2. Do not over load DG set.
3. Do not allow unauthorised person to operate the DG.
4. Don't wash acoustic enclosure from inside.

Troubleshooting Gensets 

GENSET
No.	PROBLEM	CHECK & ACTION TO BE TAKEN
1	Engine does not CRANK when start PB is pressed.	Batteries are very weak. Check whether start relay operates.
		Use properly charged batteries
	OR	Fault in starter motor
	The engine doesn't start but cranks.	Air lock in fuel system.
		Restriction in a fuel pipe.
		Before engine starting ensure that load switch (MCCB) is off.
2	High water temperature Indication lights and engine stops.	Temp. switch end wire may be on body earth. Temp. switch may be faulty. Actual water temp. may be high. No water in radiator. Water circulation system may be faulty.
3	Charge fail indication 'ON'	Check if 'IND' terminal is connected properly. Check the wiring. Check alternator is developing voltage or not.
4	Engine fires and stops after sometime and LOP indication lights.	Lop Switch end wire is not working properly. Actual Lub oil pressure is not developed. Pressure switch connecting wrong. Wiring is not correct. No oil in engine. Lub oil pipe not connected to gauge.
5	Engine overspeed indication (Frequency based)	Check genset supply to control unit. Check engine rpm. Check for loose connections.
6	Low Fuel level	Check fuel level in day tank and fill as required.
		Ensure Fuel Transfer pump (if fitted) is operating as described in the User manual.
7	Overvolts	Disconnect generators from load and restart.
		Check voltage on panel meters. If voltage is normal ensure that the load is non capacitive (power factor correction equipment may lead to a capacitive load).
		If voltage remains high and cannot be adjusted to the normal level refer to the alternator section in the User manual.

 

BATTERIES
No.	SYMPTOM	POSSIBLE FAULT	ACTION
1	No charging current	Incorrect or bad battery connections.	Check connections and clean terminals.
		No mains supply	Check mains supply to charger.
2	Charging rate too low	Low mains voltage	Check mains voltage supply.
		Loose heavy current connections	Check and tighten connection if necessary.

 

 

ENGINE
No.	TROUBLE	CAUSE	REDRESS
1	Engine does not start.	No fuel in tank.	Fill in fuel, vent fuel system.
		Air in fuel system.	Vent fuel system.
		In sufficient speed of starter.	Charger batteries.
2	Engine starts up but stop after brief time.	Fuel tank cock closed.	Open cock.
		Dirt in primary fuel cleaner or in fuel filter.	Clean or change filter cartridge respectively.
		No fuel in tank, no conveyance of fuel.	Fill in fuel, vent fuel system, inspect correct operation of fuel pump, replace if necessary, and check safe venting of tank.
		Water or dirt in fuel system.	Clean fuel tank, fill in clean fuel, replace filter, and vent fuel system.
3	No power and misfiring of engine.	Interruptions of air supply or heavy jamming of air filter.	Inspect, replace if necessary, or clean.
		Air in fuel system.	Vent fuel system.
		Fuel filter jammed.	Change filter.
		Starts of fuel supply missed.	Reset start of fuel supply.
		Defect of exhaust brake.	Inspect and repair.
4	Engine grows excessively hot.	Slipping of V-belts / V-belts broken.	Tighten or replace V-belts.
		Defect of temperature governor.	Emergency operation; forced opening of valve plate.
		Defect of temperature controller.	Perform electrical check of temperature controller.
		Lack of coolant.	Fill in coolant.
		Radiator is dirty.	Clean radiator.
		Mis-setting of fuel supply.	Set correct engine in fuel supply.
		Intake or exhaust system jammed.	Redress cause of trouble.
		Heavy dirt accumulation on cylinder elements.	Consult workshop.
5	Irregular speed of engine.	Defect of speed governor.	Inspect fuel injection pump and governor.

 

 

SYSTEM TROUBLESHOOTING
No.	STEP TERMINALS	NORMAL READING	PROBABLE CAUSE OF ABNORMAL READING
1	E (+) & F (-)	Battery Supply Voltage 12 or 24V DC	1. DC battery power not connected. Check for blown fuse.
			2. Low battery voltage.
			3. Wiring error.
2	A (+) & B (-)	0-3.9 with speed trim	1. Speed trim shorter or mis-wired.
		7.1-7.9 without speed trim	2. Defective unit.

 

 

BRUSHLESS ALTERNATORS
No.	FAULT	CAUSE	REPAIR
1	No voltage build - up	Insufficient residual voltage	Excite the rotor using a battery.
		Improper connection	Correct the connection.
		Low speed	Reset the speed to the nominal.
		Faulty Winding	Check the winding resistance and rewind if required.
		Rotating rectifier failure	Replace the rotating rectifier.
		Faulty AVR	Replace the AVR.
2	Voltage oscillations	Incorrect AVR setting	Set the AVR stability pot.
		Thyristor load more than specified limits	Reduce the Thyristor load.
		Insufficient engine flywheel
3	Unbalanced Voltage	Unbalanced load	Correct the load.
		Loose connections	Tighten the loose connections.
		Stator winding faulty	Check winding resistance & rewind if required.