11 Wrong Ways to Operate Diesel Generators

Oct. 14, 2021

Today, Dingbo Power a diesel generator set manufacturer, summarized the 11 incorrect operating methods of diesel generators as follows:

 

(1) After a cold start, run with load without warming up.

 

When the diesel engine is cold-started, due to the high oil viscosity and poor fluidity, the oil pump is insufficiently supplied, and the friction surface of the machine is poorly lubricated due to lack of oil, causing rapid wear and even failures such as cylinder pulling and tile burning.Therefore, the diesel engine should run at idling speed and heat up after cooling and start, and then run with load when the standby oil temperature reaches 40℃ or higher; the machine should start with low gear and drive for a certain mileage in each gear in sequence until the oil temperature is normal and the fuel supply is sufficient. , Can be converted to normal driving.

 

(2) Diesel engine runs when the oil is insufficient.

 

At this time, insufficient oil supply will cause insufficient oil supply on the surface of each friction pair, resulting in abnormal wear or burns. For this reason, it is necessary to ensure sufficient oil before the machine starts and during the operation of the diesel engine to prevent cylinder pulling and tile burning failures caused by oil shortage.

 

(3) Sudden stop with load or stop immediately after sudden load removal.

 

After the diesel engine is turned off, the circulation of the cooling water stops, the heat dissipation capacity is drastically reduced, and the heated parts lose cooling. It is easy to cause the cylinder head, cylinder liner, cylinder block and other mechanical parts to overheat, produce cracks, or cause the piston to over-expand and become stuck in the cylinder liner. On the other hand, if the diesel engine is stopped without cooling at idle speed, the friction surface will not contain enough oil. When the diesel engine is restarted, it will aggravate wear due to poor lubrication. Therefore, before the diesel engine stalls, the load should be unloaded, and the speed should be gradually reduced and run for a few minutes without load.

 

(4) After the diesel engine is cold started, the throttle is blasted.

 

If the throttle is slammed, the speed of the diesel engine will rise sharply, which will cause some friction surfaces on the engine to wear out due to dry friction. In addition, the piston, connecting rod, and crankshaft receive large changes when the throttle is hit, causing severe impacts and easily damaging parts.


11 Wrong Ways to Operate Diesel Generators

 

(5) Run under the condition of insufficient cooling water or too high temperature of cooling water or engine oil.

 

Insufficient amount of cooling water in diesel engines will reduce its cooling effect. Diesel engines will overheat due to ineffective cooling; excessively high cooling water and engine oil temperature will also cause diesel engines to overheat. At this time, the main thermal load of cylinder head, cylinder liner, piston assembly and valve, etc. will decrease sharply, and its mechanical properties such as strength and toughness will decrease sharply, which will increase the deformation of parts, reduce the matching gap between parts, and accelerate the wear of parts. There will also be cracks and malfunctions such as machine parts jamming.Excessive temperature of cooling water and engine oil will accelerate engine oil aging and deterioration, and reduce engine oil viscosity. The conditional lubrication conditions of cylinders, pistons and main friction pairs will deteriorate, resulting in abnormal wear. The overheating of the diesel engine will worsen the combustion process of the diesel engine, causing the injector to work abnormally, poor atomization, and increasing carbon deposits.

 

(6) Run under the condition that the temperature of cooling water and engine oil is too low.

 

During the operation of the diesel engine, the temperature of the cooling water is too low, and the temperature of the cylinder wall drops accordingly. The water vapor produced by the combustion condenses into water droplets. It contacts the exhaust gas to generate acidic substances, which adhere to the cylinder wall and cause corrosion and wear. Practice has proved that when the diesel engine is often used at the cooling water temperature of 40℃~50℃, the wear of its parts is several times larger than that of the normal operating temperature (85℃~95℃).At this time, when the water temperature is too low, the temperature in the cylinder is low, and the ignition delay period of the diesel engine is prolonged. Once a fire occurs, the pressure rises rapidly, and the diesel engine fuel is rough, which may cause mechanical damage to the parts. The diesel engine has been running under the condition of low cooling water temperature for a long time, and the gap between the piston and the cylinder liner has been large, knocking has occurred, and vibration has occurred, causing the cylinder liner to appear cavitation. The oil temperature is too low, the oil viscosity is high, the fluidity is poor, and the lubrication part is insufficient oil, which makes the lubrication worse, causes the friction pair wear to increase, and shortens the service life of the diesel engine.

 

(7) Run under the condition of low oil pressure.

 

If the oil pressure is too low, the lubrication system cannot carry out normal oil circulation and pressure lubrication, and sufficient oil cannot be obtained for each lubrication part. Therefore, when the machine is running, pay attention to observe the oil pressure gauge or the oil pressure indicator light. If it is found that the oil pressure is lower than the specified pressure, stop immediately and continue driving after troubleshooting.

 

(8) Speeding and overloading of the machine.

 

If the machine is seriously overspeeding or overloading, the diesel engine will run under the working conditions of excessive load and high speed, which may cause rough work. The thermal load and mechanical load of cylinder liners, pistons, connecting rods, etc. will increase, and it will be easy to cause tension. Failure of cylinder, burning tile, etc. Frequent overload operation can cause long-term rough combustion in the cylinder and easily damage the cylinder head gasket.

 

(9) Boom the throttle before stalling.

 

If a high-speed diesel engine suddenly stops running, its huge inertia will damage the crank connecting rod mechanism and the parts of the valve mechanism and shorten the service life. At the same time, the fierce blast of the throttle is that fuel flows down the cylinder wall due to excessive fuel entering the cylinder to complete combustion, diluting the lubricating oil. In addition, carbon deposits in the piston, valve and combustion chamber will increase significantly, causing blockage of the fuel injector and piston jamming.

 

(10) Suddenly add cooling water when the diesel engine temperature is too high

 

If the cooling water is suddenly added when the diesel engine is short of water and overheating, it will cause cracks in the cylinder head, cylinder liner, cylinder block, etc. due to drastic changes in cold and heat. Therefore, when the temperature of the diesel engine is too high, the load should be removed first, the speed should be increased slightly, and the diesel engine should be turned off after the water temperature drops, and the water radiator cover should be loosened to remove water vapor. If necessary, slowly inject cooling water into the water radiator.

 

(11) Long-term idling operation.

 

When the diesel engine is idling, the lubricating oil pressure is low, and the cooling effect of the oil injection on the top of the piston is poor, which causes a sharp increase in wear and easy cylinder pulling; it can also cause poor atomization, incomplete combustion, serious carbon deposits, and sometimes even jamming of valves and piston rings , Cylinder liner cavitation. For this reason, some diesel engine operating instructions clearly stipulate that the idling time of the diesel engine shall not exceed 15-20min.

 

The above are the 11 wrong operating methods of diesel generators shared by Dingbo Power. Friends who need to buy diesel generators, welcome to contact us by email dingbo@dieselgeneratortech.com, we will definitely serve you wholeheartedly.


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