The Most Common Solutions to Industrial Diesel Generator Problems

There are many reasons why industrial diesel generators fail. When operating in an industrial environment, you need to anticipate and prepare for the inevitable. The following are some of the most common solutions to repair industrial diesel generator problems.  

Coolant level drop alarm/stop  

The most obvious cause of coolant level reduction is external or internal leakage. Many industrial diesel generators are equipped with this alarm, but few have a dedicated alarm indicator for when coolant is low.  This alarm is usually associated with overheated coolant outages. If the generator is equipped with a near high coolant alarm or a high Coolant forecast alarm, you can identify the fault that caused the shutdown. 

 The Most Common Solutions to Industrial Diesel Generator Problems 

Cylinder block heater  

The block heater actually heats the coolant that circulates around the engine block. Keeping the engine block warm will prevent the oil from becoming too thick at low temperatures. A common misconception is that engines do not need heaters in warm climates. Block heaters don't just help start engines in cold weather. Because of the metals used in engine construction, wear accelerates during startup. Pistons are usually made of aluminum and expand faster than iron liners. This rapid expansion of the piston can cause the piston skirt to wear. The block heater reduces most of the wear by keeping the cooling system warm and the cylinder liner inflated.  

Coolant temperature drop alarm  

The cooling liquid temperature drop alarm is mainly caused by the failure of the heating block. These heaters operate 24 hours a day, seven days a week, and often fail. However, the integrated heater does not stop the engine. The extreme temperature inside the body heater is the cause of coolant circulation in the system. Sometimes, you will hear the coolant boiling in the cylinder heater.  

Oil, fuel, or coolant can be prevented through regular maintenance 

Leaks. In most cases, the leak is not a real leak, but the result of wet accumulation. Wet accumulation is the accumulation of carbon particles, unburned fuel, lubricants, condensates and acids in the exhaust system.  

The most common coolant leaks occur in cylinder heater hoses. Block heaters produce extreme temperatures that accelerate heater hose fatigue.  

The most common fuel leak service call is caused by overfilling the bottom tank. This is usually caused by human error or pump system failure. To prevent this, it is always recommended to have industrial diesel generators refueled by trained professionals.  

Industrial diesel generators have a control panel. The panel controls all aspects of setting up, operating and shutting down industrial diesel generators. caused the generator to shut down. The non-automatic generator control service call is a direct result of human error.  

The obvious reason is that the master switch is in the off/reset position. The control switch has off/reset, cooling and other positions, which will cause the industrial diesel generator to be unable to start when the power failure occurs. Alarms should sound at these locations.  

The alarm is not reset, the circuit breaker is not reset, the switchgear is not reset, the emergency stop button is activated, and so on are examples of non-automatic failures. Multiple generators are configured to short-circuit the main circuit breaker during an emergency stop. If the industrial diesel generator shuts down automatically (for some reason), someone needs to physically reset the control panel to clear the alarm. 

Fuel return tank/generator does not start  

This is a common problem with irregular use of new engines. To meet today's emissions requirements, the margin of error within the fuel system is reduced, making the fuel system more susceptible to air, which can affect the start-up ability of the generator. This is not common in older generators. Older industrial diesel generators with this problem can leak in pipes and check valves and fail to retain fuel properly in the engine.

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