Several Common Diesel Generator Problems and Solutions

In various application scenarios of modern society, diesel generator sets, as crucial power supply equipment, play a vital role in maintaining production and daily life order. However, diesel generators inevitably encounter various faults during operation. How to quickly identify and resolve these problems is key to ensuring the efficient and reliable operation of the equipment. Below are some common diesel generator problems and their solutions.

Before delving into generator maintenance techniques, it is fundamental to comprehend the basic structure and working principle of a diesel generator. A diesel-powered generator set is primarily composed of a diesel engine, an alternator, a control system, and auxiliaries. The diesel engine generates power through the combustion of diesel, which in turn drives the alternator to rotate, thereby converting mechanical energy into electrical energy. The control system is responsible for monitoring the operational status of the generator set and adjusting output voltage, frequency, and other parameters as required. Auxiliaries include the cooling system, lubrication system, fuel system, among others, all of which work in concert to ensure the safe and stable operation of the unit.

Common faults and solutions of diesel generators

Generator won’t start

Diesel generator not starting is one of the common problems. There can be a multitude of reasons for generator failing to start, including: a dead or weak battery, a faulty starter motor, a problematic fuel system, clogged air intake, defective glow plugs, etc.

To troubleshoot the problem, you can use a multimeter to check the battery for its charging level and delivery voltage. Also inspect if the battery cables are loose or corroded. Make sure the generator battery is in good condition. Then check if the starter motor engages and turns the engine properly. If they work normally, check whether the fuel system is unobstructed. Inspect whether the fuel filter is blocked and whether the fuel pump is working properly. Check the air filter and replace it if it looks dirty.

Generator underpower

Insufficient power is manifested when the diesel generator set's output voltage or current during operation falls below the rated value. Potential causes include insufficient fuel supply or issues with the fuel system, faults in the generator windings, or malfunctions in the excitation system.

To deal with the problem, you can inspect whether the diesel engine's intake and exhaust systems are unobstructed and check for carbon buildup or blockages. Additionally, it is essential to examine whether the engine's fuel supply system is working correctly and whether the fuel injectors are clogged or worn. Furthermore, check whether the generator's windings are in good condition and check the windings for any short circuits or open circuits. The voltage and current of the excitation system should also be within the normal range to ensure that the generator can deliver sufficient power.

Voltage fluctuations

Voltage fluctuation refers to the instability of the output voltage of a diesel generator set during operation, where the voltage oscillates between high and low levels. Potential causes include a malfunctioning voltage regulator, instability in the excitation system, or excessive load variations, etc.

To fix this problem, you can check the operational status of the voltage regulator to determine if it can automatically adjust the output voltage in response to load changes. At the same time, it is crucial to inspect the stability of the excitation system to ensure that the excitation current and voltage remain steady. Additionally, attention should be paid to the variations in load to prevent voltage fluctuations caused by either excessively high or low loads.

Generator overheating

Overheat protection is a measure implemented by generator sets to safeguard themselves from damage. When the operating temperature of a diesel generator becomes excessively high, it will automatically shut down and trigger an alarm. Reasons for this problem may include malfunctions in the cooling system, issues with the lubrication system, or excessive load.

To fix the issue, you can inspect the operational status of the generator cooling system, including checking whether the radiator is clogged, whether the coolant is at an adequate level, and if the water pump is functioning correctly. Meanwhile, it is essential to check the condition of the lubrication system to ensure that the engine oil is sufficient and of good quality. Additionally, attention should be given to the magnitude of the load to prevent prolonged overload operation that could lead to overheating of the generator set.

The maintenance of diesel generator sets is a complex and meticulous task that requires maintenance personnel to possess extensive professional knowledge and practical experience. By understanding the equipment structure, mastering troubleshooting methods, conducting regular inspections and maintenance, preparing spare parts, and providing professional training, the operational efficiency and reliability of diesel electric generating sets can be significantly enhanced. Hope the practical techniques shared in this article will offer valuable reference and assistance to you.