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Common Diesel Generator Injector Faults And Troubleshooting

Nov. 15, 2022

Jiangsu Starlight Electricity Equipments Co.,Ltd. Guide: The so-called fuel injector is a precision device with very high precision. It mainly receives the fuel injection pulse signal sent by ECU and accurately controls the fuel injection amount. Common diesel generator injector failures include the following seven types:

 

Fault feature 1: little or no fuel injection.

 

Possible causes:

(1) There is air in the fuel system circuit.

(2) The fuel injection nozzle couple is seized.

(3) The fuel supply of the fuel injection pump is not normal.

(4) The fuel system leaks heavily.

(5) The fuel injection nozzle parts are worn.

 

Troubleshooting:

(1) Remove the air from the low-pressure or high-pressure oil pipe.

(2) Have professional maintenance personnel check or replace the fuel injection nozzle.

(3) Find out the cause according to the troubleshooting method of the fuel injection pump and check, repair or replace the corresponding parts.

(4) Have the professional maintenance personnel check and replace the nozzle coupling.


diesel generator

 

Fault feature 2: low injection pressure.

 

Possible causes:

(1) The pressure regulating screw of fuel injector is loose.

(2) The pressure regulating spring of fuel injector is deformed or broken.

(3) The injector needle valve is stuck.

 

Troubleshooting:

(1) Have the professional maintenance personnel readjust to the specified pressure and tighten the lock nut.

(2) Have the professional maintenance personnel replace the fuel injector spring.

(3) Have the professional maintenance personnel replace the fuel injection nozzle coupling.

 

Fault feature 3: The injection pressure is too high.

 

Possible causes:

(1) The pressure regulating spring of fuel injector is too elastic.

(2) The injector needle valve is stuck.

(3) The orifices are carbon deposited or blocked.

 

Troubleshooting:

(1) Have professional maintenance personnel readjust to the specified pressure.

(2) Have the professional maintenance personnel replace the fuel injection nozzle coupling.

(3) Have professional maintenance personnel clean the nozzle or replace the fuel injector.

 

Fault feature 4: Fuel injector leaks.

 

Possible causes:

(1) The pressure regulating spring of the fuel injector is broken.

(2) The grinding surface of the fuel injection nozzle needle valve body is damaged.

(3) The injection nozzle needle valve is locked.

(4) The fuel injector cap is deformed.

(5) Leakage is caused by poor contact between the fuel injection nozzle and the sealing plane of the fuel injector body.

 

Troubleshooting:

(1) Have the professional maintenance personnel replace the fuel injector spring.

(2) Have the professional maintenance personnel replace the fuel injection nozzle coupling.

(3) Have the professional maintenance personnel replace the tight cap.

(4) Have professional maintenance personnel repair or replace the fuel injection nozzle coupling, and replace the fuel injector if necessary.

 

Fault feature 5: poor atomization of fuel injection.

 

Possible causes:

(1) The force of the pressure regulating spring decreases or the spring breaks.

(2) The seat surface of the fuel injection nozzle is worn.

(3) There is garbage on the mating surface of the fuel injection nozzle.

(4) The fuel injection nozzle coupling is deformed or worn.

(5) The injection nozzle needle valve is locked.

 

Troubleshooting:

(1) Have the professional maintenance personnel replace the fuel injector spring.

(2) Have professional maintenance personnel repair or replace the fuel injection nozzle coupling.

(3) Have them cleaned by professional maintenance personnel.

(4) Have the professional maintenance personnel replace the fuel injection nozzle coupling;

 

Fault feature 6: injection lines or drops.

 

Possible causes:

(1) The orifices are carbonized and blocked.

(2) The seat surface of the fuel injection nozzle needle valve body is excessively worn.

(3) The injection nozzle needle valve is locked.

 

Troubleshooting:

(1) Have professional maintenance personnel clean the nozzle and replace the injector if necessary.

(2) Have the professional maintenance personnel replace the fuel injection nozzle coupling.

 

Fault feature 7: The needle valve surface is burnt or blue black.

 

Possible cause: The diesel engine is overheating.

 

Troubleshooting: check the cooling system, and do not overload the diesel generator for a long time. Have professional maintenance personnel check the fuel injection nozzle coupling and replace it if necessary.

 

Jiangsu Starlight Electricity Equipments Co.,Ltd. has a young and professional technical backbone team, with an average working age of more than 10 years in the generator unit industry. There are 64 sales and service departments throughout the country to provide users with a one-stop service of machine room design, equipment supply, commissioning and maintenance at any time. No matter when and where, a well-trained service team will provide you with comprehensive and considerate protection. For more details, please contact us with sales@dieselgeneratortech.com.


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