We have a Perkins diesel engine in a generator.Running hrs 5000 now giving problem that exhaust manifold and turbocharger gets red hot on load. air filter new. after cooler cleaned.now leakage in intake found. high fuel consumption reported and black smoke on load. can we rectify this fault by replacing injectors.any other cause.

We are Perkins diesel generator OEM and can provide 22KW to 1800KW Perkins diesel generator including open type,silent type and container type genset. Each genset has its user's manual.

Normal starting procedure of Perkins Generator set

1. As far as possible do not start the generator set under load conditions.

2. Transfer the key switch to the starting (STAR) position. The engine should start immediately.

3. After the engine starts, return the key switch to the running (RUN) position. If the engine has not started after 10 seconds, turn the key switch back into operation and (RUN) for 10 seconds. Then repeat steps 2 and 3. If the engine is still unable to start after three attempts, please find out why.

4. After engine starts, follow steps 4.a and 4.b.

A. Check the oil pressure.
B. Check the machine for leaks.
C. Make sure the battery is charged.
D. After running the engine for five minutes, check the generator monitoring system. Make sure the engine works properly before loading.

Note: do not use ether-like spray starting aids in cold weather. Otherwise, it could lead to explosion and personal injury.

The use of water jacket heaters or extra battery capacity improves the machine's start-ability below 10 ?.

Methods for checking and cleaning the core of the rear cooler of Perkins generator set

Check for damage, corrosion, dirt, grease, insect stains, leaves, oil and other debris on the cooler. Clean the cooler if necessary.

https://www.dieselgeneratortech.com/generator-sets/Instruction-for-Perkins-Generator-Set-Maintenance.html

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We are Perkins diesel generator OEM. Can provide 22KW to 2200KW diesel generator set with Perkins engine. https://www.dieselgeneratortech.com/perkins

Ensure any engine control switch is set to the run position, with the load disengaged. Manually set the air shut off valve (if fitted) to the run position (see Fig. 18), Turn the key switch to the start position, which will energize the solenoid allowing the engine to crank over for a few seconds then start.

Check the instrument panel is showing normal running oil pressure, and the ammeter for charge to the engine batteries.
Allow the engine to run for five minutes checking the instruments are reading correctly. Stop the engine and check the oil and coolant levels, replenish if necessary.


https://www.dieselgeneratortech.com/generator-sets/normal-starting-procedure-of-Perkins-generator-set.html

Hello. Maybe you have solved your problems. But I still want to share the helpful article to you. https://www.dieselgeneratortech.com/diesel-generators/why-diesel-generator-fail-to-start.html

We are Perkins diesel generator OEM. Can provide 22KW to 2200KW diesel generator set with Perkins engine. https://www.dieselgeneratortech.com/perkins

We are Perkins diesel generator OEM and can provide 22KW to 1800KW Perkins diesel generator including open type,silent type and container type genset. Each genset has its user's manual.
https://www.dieselgeneratortech.com/diesel-engines/Perkins-engines-fuel-filter-elements-and-air-filter.html

Pump

It is quite normal for the exhaust manifold and turbo to get very hot, especially when the engine is working hard running at high speed under load. Every time the mixture in the cylinder is ignited there is a small explosion producing a BIG flame and a lot of heat to push the piston down. A lot of this heat goes out the exhaust. During daylight it is usually not noticeable, but at night it will visibly glow up to a bright red.

In relation to the oil pressure dropping, providing the oil level is at the correct level, there may be a restriction in the gauze filter on the input of the oil pump due to sludge buildup. Once the engine warms up and the oil thins out, the oil pump can't work at maximum capacity. The drop in RPM could be caused by the turbo getting insufficient lubrication and cooling due to the low oil pressure reducing oil flow to the turbo causing it to not work at its optimum speed and efficiency and therefore through reduced air flow into the cylinders the engine would tend to loose speed especially when under high load. The drop in RPM could also be caused by a problem with fuel flow to the injector pump causing the engine to run lean which would not allow the engine to produce maximum power and also contribute to higher exhaust temperatures because the governor would have the throttle wide open to try and maintain the engine speed when the generator is required to produce maximum output.

You may have temp. sensor for a bank damaged, or its camshaft rolled over.

This system includes air cleaner, intake manifold, exhaust manifold, exhaust muffler, exhaust turbocharger ( for turbocharged diesel engine) , intercooler ( for turbocharged and inter-cooled diesel engine) and connecting pipes.

valve or exhaust arresting device installed after the primary filter to take off the dust from filtering. The resistance of the air cleaner should not be too big, the allowable max. resistance under its stained condition is 3kPa, and that under its stained condition is 5kPa. There is maintenance indicator mounted at the vent port of air cleaner, when red signal is given that means maintenance or replacement should be taken place in time, otherwise the performance and service life will be influenced.

I take it it's diesel. Have you renewed filters? Bleed fuel system Make sure there is plenty of diesel flowing out of tank (pipe not blocked) Check lift pump working