Causes of Faults in Diesel Generator Sets

Diesel generator sets, capable of providing continuous, stable, and safe electrical power, are widely used as emergency backup power sources in sectors such as telecommunications, finance, hospitals, schools, and commerce. They can also serve as the primary independent power supply in remote areas. During operation, diesel generating sets inevitably encounter faults and damage. To ensure normal operation, users need to fully understand the causes of generator faults and implement preventive measures. Below, let's explore the various causes of faults in diesel generators.

A generator set mainly consists of three parts: the engine, the AC synchronous generator, and the control panel. Among these, the engine, which generates power for the genset, is the most prone to faults. The causes of faults in diesel generator sets are diverse but ultimately boil down to two aspects: internal causes and external causes.

Internal causes of faults in diesel generator sets

1. Properties of materials and fuels/lubricants

During the design and manufacturing process, selecting the correct materials based on the working nature and characteristics of generator set components is crucial. Incorrect material selection, use of materials that do not meet specifications, or inappropriate substitutions are primary reasons for phenomena such as wear, corrosion, deformation, fatigue damage, cracking, and aging in components. For example, Dingbo Power's after-sales team discovered during customer follow-ups that some users later replaced air filters with non-original parts, leading to generator failures, or used batteries that did not meet specifications, causing battery explosions.

The properties of various materials and fuels/lubricants used in the diesel generating sets generally fall into three categories: physical, chemical, and mechanical properties. Many genset faults result from the influence of external factors acting through these properties. For instance, metal materials can deform, crack, or even break under excessive force; oxidize under high temperatures; and suffer fatigue damage under various loads. Non-metallic materials can age. Acidic substances in fuels/lubricants can corrode metals and cause the oils to deteriorate. Users should regularly check the fluid levels and quality and replace the fuel/oil and filters promptly.

2. Structural characteristics of components

Components of the diesel generator set have their own unique structural forms. During operation, external factors often act through these characteristics, causing related components to fail. For example, due to the inherent structural features of the engine water jacket, cooling water tends to form scale on the outer wall of the cylinder liner under high temperatures, thereby affecting the cooling efficiency of the cylinder liner.

3. Operational characteristics of components

Direct contact and relative motion between components lead to wear due to friction. For instance, the piston rings in a diesel engine are in direct contact with the cylinder. During operation, the high-speed reciprocating linear motion of the piston rings within the cylinder causes cylinder wear. Engine components experiencing severe temperature fluctuations during operation can deform or crack due to thermal stress. For example, during diesel generator operation, the cylinder block and cylinder head, subjected to high temperatures, undergo redistribution of internal stress to reach a new equilibrium, resulting in warping deformation of the cylinder block and cylinder head surfaces.

External causes of faults in diesel generator sets

1. Improper operation

Operators fail to use the diesel generator sets according to operating procedures. Practices such as frequent low-speed operation, rapidly increasing load without warming up the engine, and low oil pressure can accelerate component wear. Excessive operating hours, significant load fluctuations, and prolonged operation under overload conditions of diesel generator can also lead to premature component failure.

2. Poor maintenance

During generator maintenance, failing to complete various tasks strictly according to specified technical requirements or employing incorrect operational methods can lead to human-induced faults. During routine diesel generator maintenance, it is essential to replace oils promptly, regularly clean the air filter and remove scale from the radiator, etc. Perform the daily maintenance and the first, second, and third levels of maintenance for the diesel generator set as required.

3. Substandard repair quality

During the repair process, improper machining that fails to meet repair technical requirements—such as incorrect component fit clearances, inadequate surface finish, or insufficient cleaning during assembly—can cause the generator set to develop faults during operation. The mutual positional accuracy between components during assembly is also crucial. Failure to meet requirements can induce additional stress, cause issues like abnormal wear, and accelerate component failure.

The above are the various reasons leading to faults in diesel generator sets. After understanding these causes, users can implement effective preventive measures, such as establishing a reasonable maintenance system and conducting regular comprehensive inspections and maintenance of the generator set. Regularly train operation and maintenance personnel to ensure they are familiar with the operational and maintenance knowledge of the generator set, avoiding faults caused by improper operation. When replacing parts, users should try to choose original factory parts to ensure equipment compatibility and performance. When encountering faults, promptly contact a professional service team for inspection and maintenance.

As a professional manufacturer of generator sets, Dingbo Power is committed to providing high-quality generator sets to global customers. All configurations are composed of original factory components. All our diesel generators undergo factory testing before leaving the factory, and we offer reliable after-sales service. In case of faults, we can respond quickly to help customers resolve issues promptly. If you have any needs, please feel free to contact Dingbo Power today.