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Diesel generator generator common faults and their elimination methods
Diesel generator set in the process of long-term use, there may be various failures.
Here are some common faults and their troubleshooting methods:
1. The generator set cannot be started
Cause of failure:
The battery is low or faulty.
The starting motor is damaged.
Insufficient fuel or clogged fuel system.
The control system is faulty.
Elimination method:
Check the battery voltage and charge or replace the battery if necessary.
Check the connection wire of the starter motor to ensure good contact and repair or replace it if necessary.
Check the fuel system to ensure that fuel is sufficient and the oil line is smooth.
Check the fuses and circuits of the control system to ensure that they are not broken or damaged.
2. The diesel generator set cannot reach the rated power
Cause of failure:
The load is heavy.
Diesel engine performance decline (such as fuel injection system, air filter, oil pump failure, etc.).
The generator stator winding is faulty.
Voltage regulating device (AVR) failure.
Elimination method:
Check whether the load exceeds the rated capacity, if overloaded, reduce the load.
Inspect the fuel injection system for blockage or damage, and clean or replace the fuel injector.
Check the air filter and oil circuit to ensure smooth flow.
Check generator stator windings and brushes and repair or replace them if necessary.
Check the voltage regulator to make sure it is working properly.
3. The generator set makes too much noise
Cause of failure:
The internal mechanical parts of the generator are worn or loose.
The exhaust system is blocked or leaking.
The generator is not securely connected to the base or foundation.
Elimination method:
Check the internal mechanical parts of the generator, such as bearings, gears, etc., and replace or lubricate them if necessary.
Check the exhaust system to make sure there are no clogs or leaks, and clean or repair them in time.
Check the connection between the generator and the base and ensure that the fixing bolts are tight.
4. Abnormal vibration of diesel generator set
Cause of failure:
The generator is misaligned with the diesel engine.
Generator rotor unbalance.
The base or installation is unstable.
Elimination method:
Check that the connection between the generator and the diesel engine is correct and adjust the alignment if necessary.
Check whether the generator rotor is balanced, if it is not balanced, it needs to be balanced.
Check the generator base and base to ensure that they are stable and do not loosen.
5. The voltage is unstable
Cause of failure:
The AVR (Automatic Voltage regulator) is faulty.
Brush is in poor contact with slip ring.
Generator stator winding is short-circuited or grounded.
Elimination method:
Check if the AVR is working properly and replace or repair it if necessary.
Check the contact between the brush and the slip ring and clean or replace the brush.
Check insulation and grounding of stator windings and repair or replace faulty parts.
6. Diesel generator set overheating
Cause of failure:
Insufficient coolant or blocked cooling system.
The cooling fan is damaged or the blade is blocked.
The diesel engine is overloaded.
Elimination method:
Check coolant levels and refill or replace coolant.
Clean the cooling system and check if the radiator is blocked.
Check whether the cooling fan is working properly, clean the fan blades, or replace the damaged fan.
Confirm whether the diesel engine load is appropriate to avoid overload operation.
7. Diesel generator oil leakage
Cause of failure:
The oil seal is damaged.
Tubing and fittings are loose or damaged.
Aging of internal engine seals.
Elimination method:
Check whether the oil seals and seals are aging or damaged, and replace them in time.
Inspect tubing and joints for looseness or damage, tightening or replacement.
Check the oil level regularly and make sure there is no excess oil buildup.
8. Excessive fuel consumption
Cause of failure:
Fuel injection system failure, excessive or uneven fuel injection.
Clogged air filter, resulting in low fuel efficiency.
The generator is overloaded.
Elimination method:
Check the injector for blockage or failure, and clean or replace the injector.
Check the air filter to make sure it is unimpeded and cleaned or replaced regularly.
Confirm the load, avoid overload operation, and adjust the load appropriately.
9. Frequent tripping of generator set
Cause of failure:
Overload.
Short circuit or ground fault.
The automatic protection device is faulty.
Elimination method:
Check the load to ensure it does not exceed the rated power.
Check electrical connections to make sure there are no short circuits or ground faults.
Check automatic protection devices (such as overload protectors, current relays, etc.) to ensure that they are working properly and repair or replace them if necessary.
IN SUMMARY:
Regular maintenance and inspection can effectively avoid most failures and maintain the efficient operation of the unit
For complex faults, contact professional maintenance personnel.
