Shut Down Your Diesel Generators Immediately When these Fault Codes Appear

In the daily operations of enterprises, diesel generator sets are crucial as backup power sources, and their stable operation is paramount. However, if specific fault codes appear during operation, continuing to run the generator set is highly likely to lead to severe consequences and cause irreparable major losses. Today, Dingbo Power will detail those fault codes that necessitate an immediate shutdown and provide corresponding response strategies to help you navigate critical situations safely!

Fault codes requiring immediate diesel generator shutdown

1. Over speed

When the speed exceeds the safe threshold, the internal mechanical structure of the diesel generator set endures immense stress. Critical components like the flywheel and connecting rods may fracture due to excessive centrifugal force, potentially even causing cylinder explosion and rendering the entire generator set scrapped.

Response measures: Quickly cut off the fuel supply to stop the engine. Then, carefully inspect the governor for faults, such as a failed governor spring or a stuck control lever. Meanwhile, check if the speed sensor is damaged or transmitting abnormal signals, ensuring it can accurately feedback speed information.

2. Low oil pressure

Low oil pressure indicates that the engine's internal lubrication system is not functioning correctly. The lack of sufficient oil film between moving parts causes a sharp increase in friction, leading to severe failures like cylinder scuffing and bearing bush burning. This can significantly degrade diesel engine performance or even make it irreparable.

Response measures: Shut down the diesel generator immediately and check if the oil level is within the normal range. If the level is too low, add the appropriate specification oil promptly. If the level is normal, inspect the oil pump for damage, such as worn oil pump gears or a broken pump shaft, causing insufficient oil supply. Also, check if the filter is clogged, hindering normal oil flow.

3. High coolant temperature

Engine overheating causes uneven thermal expansion of components like the cylinder head and block, leading to cylinder head deformation and poor valve sealing, resulting in air leakage. In severe cases, pistons may melt due to excessive heat and seize to the cylinder walls, causing total engine failure.

Response measures: Shut down the generator set immediately and check if the coolant is sufficient. If coolant level is low, add an appropriate amount. If coolant is adequate, check if the cooling fan is operating normally. Failures like a damaged fan motor or a broken fan belt can reduce cooling efficiency. Also, inspect the water pump for faults, such as a damaged impeller or a broken pump shaft, affecting coolant circulation.

4. Over/under voltage

Unstable voltage can damage connected electrical equipment, harming components and shortening their service life. Furthermore, excessively high voltage can break down the insulation of the generator windings, causing short circuits. Excessively low voltage results in insufficient generator output power, affecting the normal operation of equipment.

Response measures: Check if the Automatic Voltage Regulator (AVR) is functioning correctly.  Failures like damaged electronic components or faulty regulation circuits can cause improper voltage control. Also, inspect the excitation system for faults, such as shorted excitation windings or unstable excitation current, affecting the generator's voltage output.

5. Short circuit

A short circuit generates extremely high current, instantly releasing a large amount of heat, which can cause fires, burn out the diesel generator and related electrical equipment, resulting in significant property damage and potential personal injury.

Response measures: Immediately cut off the generator output and quickly investigate line insulation issues. Check wires for damage, aging, or poor connections, and promptly repair or replace any identified fault points.

The above are several fault codes that you should pay attention to during generator operation. If one of them occur, you can press the Emergency Stop button and then cut off fuel and power. Record the fault code and contact professional technical personnel. Do not attempt to disassemble and repair the generator set yourself.

Prevention recommendations

Regular maintenance: Perform maintenance on the diesel generator set according to the specified schedule or running hours. Regularly replace consumables like oil and filters to ensure internal cleanliness and proper lubrication, extending the service life of the generator set.

Install an intelligent monitoring system: Utilize an intelligent monitoring system like Dingbo Cloud Management System to track the generator set's operating parameters in real-time, such as speed, oil pressure, coolant temperature, and voltage. If abnormalities are detected, the system can provide early warnings, prompting operators to take appropriate measures and prevent failures.

Operator training: Provide professional training for operators, familiarizing them with the operating procedures and the meanings of alarm codes. Enhance operators' emergency response capabilities to ensure they can take swift and correct actions when faults occur.

Safety is the cornerstone of enterprise development, and the safe operation of diesel generator sets cannot be overlooked. When encountering the fault codes mentioned above, be sure to shut down the diesel generators immediately and contact after-sales service for handling. Never take chances to avoid causing irreparable losses.