Fault Diagnosis of Diesel Generator Starter Not Stopping Rotation

The diesel generator starter does not stop rotating, which means that when the diesel engine starts and the ignition switch is released, the starter still continues to rotate. The causes, diagnosis, and handling methods of such faults are as follows.

Fault phenomenon: After starting the diesel engine, release the ignition switch and the starter will continue to rotate

1. One way clutch stuck

2. The starter gear return spring is too weak or broken

3. Drive gear and flywheel ring gear are stuck

4. Improper installation of the starter motor with too small tooth side clearance

5. Sintering of electromagnetic switch contacts or weak elasticity of iron core return spring

6. Sintering of starting relay contacts

7. Short circuit of ignition switch

Handling method:

1. Repair or replace the one-way clutch

2. Repair or replace the one-way clutch

3. Check if the battery is running low or if the connecting wires of the terminals are loose or if the gears are rough

4. Reinstall or inspect the starter motor

5. Repair or replace electromagnetic switch related components

6. Repair or replace the starting relay

7. Repair or replace the ignition switch

When encountering such faults, the ignition switch should be immediately turned off to turn off the diesel generator. If the starter also stops rotating after the engine is turned off, it is necessary to check whether the installation of the starter is correct, whether the tooth side gap between the drive gear and the flywheel is too small, or whether the one-way clutch is stuck (this fault causes a scream after starting), and whether the drive gear of the starter is biting against the flywheel ring gear.

If the starter still runs at high speed after the diesel generator is turned off, the power should be immediately cut off, otherwise it may burn out the starter and cause the battery to run low. This type of malfunction is generally caused by the sintering of electromagnetic switch contacts or insufficient elasticity of the iron core return spring. For starting systems equipped with relays, faults may also be caused by sintering of the starting relay contacts or short circuits in the ignition switch, and can be checked item by item. For the starting circuit with a combination relay, the failure of the protective relay is caused by the starter continuing to rotate when the operator does not release the key after starting the diesel engine. The causes and handling methods of this malfunction are as follows:

Fault phenomenon: After starting the diesel engine with a combination relay starting circuit, the operator did not release the key and the starter continued to rotate.

Possible reasons:

Combination relay failure

Reason:

1. Protection relay contact sintering, excitation winding open circuit or short circuit

2. Poor grounding

Handling method:

1. Repair or replace the combination relay

2. Clean the grounding wire or replace it

AC generator malfunction

Reason:

1. Silicon rectifier component breakdown, no voltage at center point N

2. The connection wire between the generator terminal N and the combination relay terminal N is broken or poorly connected

3. Charging indicator light to combination relay connection wire grounded

Handling method:

1. Repair or replace silicon rectifier components

2. Replace the connecting wires or clean the wiring terminals and tighten them

3. Replace the connecting cable.

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