Diesel generators are a kind of common backup power supply in our work and life. They are mainly used in highway toll stations, long highway tunnels, and various enterprises and institutions. Diesel generators can provide us with stable and reliable power supply, so regular maintenance can improve the service life of diesel generators and give full play to the working efficiency of diesel generators.
In order to further let everyone learn about diesel generators, the following will explain the troubleshooting and maintenance of common faults of diesel generators, in order to further improve the efficiency of diesel power generation and improve the business skills of equipment maintenance personnel.
1. The engine has poor ignition or the engine stalls at low speed. Common causes are low fuel pressure, air entering the fuel system, and fuel injector failure.
Exclusion method：
(1) Make sure that there is fuel in the fuel tank. Check the oil pipe between the fuel tank and the fuel delivery pump for oil leakage or severe bending. Check whether there is air in the fuel system, whether the fuel bypass valve is sticky, stuck or damaged, and check the fuel pressure. At full load speed, the minimum outlet pressure of the fuel delivery pump must be 415 kPa. The pressure in the two fuel manifolds must be 415 to 450 kPa. If the fuel pressure is lower than the above pressure, a new filter should be installed. If the fuel pressure is still low, check the fuel delivery pump and the fuel pressure regulating valve at the fuel manifold.
(2) Find out where the air leaks into the fuel system and fix it. If there is air in the fuel system, it usually enters from the suction end of the fuel delivery pump.
(3) When the engine is running at low speed, the temperature of the exhaust manifold port can be used as an indication of the condition of the injector. The low temperature of a certain exhaust manifold port is a sign that no fuel is injected into the cylinder. In this case, the injector may be faulty. The ultra-high temperature of a certain row of air manifold ports may be a sign that too much fuel is injected into the cylinder, or it may be caused by a malfunction of the injector.
2. Insufficient engine power. Common causes are poor fuel quality or water in the fuel, low fuel pressure, and air leakage in the intake system.
Exclusion method：
(1) Remove the fuel from the fuel tank, replace it with a new fuel filter, and inject clean fuel.
(2) Make sure that there is fuel in the fuel tank, and check the oil pipe between the fuel tank and the fuel delivery pump for oil leakage or bending. Check if there is air in the fuel system, whether the fuel bypass valve is stuck, and then check the fuel pressure. At full load speed, the minimum outlet pressure of the fuel delivery pump must be 415 kPa, and the pressure in the two fuel manifolds must be 415 to 450 kPa. If the fuel pressure is lower than the above pressure, the filter should be replaced. If the fuel pressure is still low, the fuel pressure regulating valve on the fuel delivery pump and fuel manifold should be checked.
(3) Check the pressure in the intake manifold to see if there is any obstruction in the air filter.
3. The vibration is too large after the engine starts. Common causes are loose or faulty shock absorbers, loose engine bearings, misalignment or imbalance of the driven equipment, etc.
Exclusion method：
(1) Check whether the shock absorber is damaged and tighten the bolts. If the bolt hole of the shock absorber is damaged, replace it with a new one.
(2) Check the alignment and balance, and make corrections if necessary.
4. The valve mechanism is noisy. Common causes are valve springs, damage to the spring clamp, damage or wear of the valve tappet, insufficient lubrication, etc.
Further reading:Exclusion method：
(1) Replace with new parts where necessary. The damaged lock clip can cause the valve to fall into the cylinder, which will cause more damage.
(2) Check the lubrication in the valve chamber. When the engine is running at high speed, a large amount of oil should flow in, while at low speed, only a small amount of oil should flow in. The oil passage (especially the passage that transports the oil to the cylinder head) must be clean.
5. There is a coolant in the lubricating oil. Common causes include damage to the organic oil cooler core, damage to the cylinder head liner or water seal, and rupture of the cylinder head.
Exclusion method：
(1) Replace with a new oil cooler core and oil filter, and inject clean lubricant.
(2) Check the protruding part of the flange of the cylinder liner, install a new water seal in the partition, and tighten the bolts used to fix the cylinder head in accordance with the technical specifications. Replace with a new cylinder head.
6. The generator overheated. Common causes are long-term engine overload and blockage of ventilation ducts.
Exclusion method：
(1) If the engine is overloaded for a long time, you should always pay attention to the instruments on the ignition panel such as power, power factor, and current. Do not overload.
(2) The ventilation duct is blocked, and the inside of the generator should be thoroughly blown clean.
7. There was too much white or blue smoke. Common causes are too much lubricating oil in the engine, piston ring wear, and damage to the oil seal of the turbocharger.
Exclusion method：
(1) Take out the oil ruler and check the oil level. When there is too much oil, drain the excess oil.
(2) Excessive wear and tear of the piston ring causes the gap to be too large, and the oil entering the combustion chamber to participate in the combustion will cause blue smoke. A new piston ring needs to be replaced.
(3) Check whether there is oil in the intake manifold and repair the turbocharger if necessary.Learn more
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