Common Faults and Solutions for Diesel Generators

Diesel generator sets are a common type of power generation equipment, widely used in industrial, agricultural, and household sectors. However, due to prolonged use as well as inadequate daily maintenance, diesel generators may also experience certain malfunctions. Below are the faults related with both the diesel engine and the alternator, along with their corresponding handling methods.

Common faults and handling methods for the diesel engine

Air in the fuel supply system: Check whether the fuel pipe joints are loose. Loosen the vent screw on the fuel filter assembly, and use the manual pump to deliver fuel until the overflowing fuel is free of air bubbles.

Blocked fuel pipeline: Check whether the fuel pipeline is clear.

Blocked fuel filter: Replace the spin-on filter element of the fuel filter assembly.

Fuel transfer pump does not supply fuel or supplies intermittently: Check whether the inlet pipe of diesel generator is leaking air and whether the filter of the transfer pump is clogged.

Insufficient fuel injection, no fuel injection, or low fuel injection pressure: Check the atomization of the sprayer, whether the fuel injection pump plunger and delivery valve are worn or stuck, and whether the plunger spring and delivery valve spring are broken. Check and adjust the fuel injection pressure to the specified range.

Faults in the starting system: Incorrect circuit wiring or poor contact, insufficient battery power: Check whether the wiring is correct and reliable. Recharge the battery.

Loose, dirty, or corroded connection of the fuel shutoff solenoid valve: Tighten, clean, or replace it.

Intake blockage: Check the air filter and intake pipe of diesel gensets. Clean or replace the air filter element.

Fuel pipeline leakage or blockage: Check the sealing condition of the fuel pipes and their connections, as well as the blockage status of the fuel filter. Replace the spin-on filter element.

Cylinder head gasket leakage: Tighten the cylinder head bolts according to the specified torque and sequence, or replace the cylinder head gasket.

Coolant temperature too high: Check and repair the radiator and regulator of diesel generator. Adjust the fan belt tension.

Excessive clearance between piston and cylinder, knocking sound at cylinder wall during operation: Replace the piston. Install a repair cylinder liner depending on the extent of wear, ensuring the specified piston-to-cylinder clearance is maintained.

Shock absorber damaged, no damping effect: Check the connecting bolts and the extent of damage. Replace them if necessary.

Turbocharger bearing damaged, rotating parts contacting housing: Replace the turbocharger assembly of the diesel generating set.

Transmission gear wear, excessive clearance. Knocking sound audible at timing gear cover: Check the gear backlash. Replace the gears depending on the extent of wear.

Coolant temperature too low: Check the thermostat's operating temperature. Replace it if necessary.

Oil viscosity too high due to low ambient temperature: Use oil of the specified grade. After starting, allow the engine to operate at low speed first. Check after the oil temperature has normalized.

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