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Common Problems And Solutions Of Industrial Diesel Generator Sets

Apr. 20, 2023

When an industrial diesel generator set is used as a common or standby power supply, it will inevitably have failure problems. Generally speaking, there are many reasons for the failure of the diesel generator set. The following are some common industrial diesel generator set failure problems and solutions that Jiangsu Starlight Electricity Equipments Co.,Ltd. has sorted out for you based on years of experience.


Low coolant level alarm or shutdown.

The most obvious cause of low coolant level is external or internal leakage. Although many industrial diesel generator are equipped with this alarm, few generators have a special alarm indicator for insufficient coolant. Usually, this alarm is associated with a shutdown due to high coolant temperature. If the generator is equipped with a "near high coolant temperature alarm" or a "high coolant temperature warning", you can determine the fault that caused the shutdown.


Leakage of oil, fuel, or coolant.

Leakage can be prevented by performing routine maintenance. In most cases, oil leakage is not actually a leak, but a result of "wet accumulation". Wet accumulation is the accumulation of carbon particles, unburned fuel, lubricating oil, condensate, and acids in the exhaust system.


The most common coolant leakage occurs in the cylinder block heater hose. Due to the extreme temperature generated by the block heater, it can lead to faster fatigue of the heater hose.


The most common fuel leakage service call is caused by overfilling the basic fuel tank. This is usually caused by human error or pump system failure. In order to prevent this from happening, it is always recommended that you have trained professionals refuel your industrial diesel generator.


Cylinder block heater.

The cylinder block heater actually heats the coolant circulating around the engine cylinder block. Keeping the engine block warm can prevent the oil from becoming too thick at low temperatures.


diesel generator set

A common misconception is that engines do not require heaters in warm climates. The cylinder block heater can not only help the engine start in cold weather. Due to the different metals used to manufacture the engine, accelerated wear may occur during the starting process. Pistons are usually made of aluminum and expand faster than iron cylinder liners. This rapid expansion of the piston can cause wear on the piston skirt.


The cylinder block heater alleviates most of this wear by maintaining the cooling system temperature and maintaining cylinder liner expansion.

Low coolant temperature alarm.


The low coolant temperature alarm is mainly caused by a heating block malfunction. These heaters are running 24 hours a day, 7 days a week, and they regularly malfunction. However, an integral heater will never cause the engine to stop running. The extreme temperature inside the body heater is the cause of coolant circulation in the system. Sometimes, you can hear the sound of coolant boiling inside the cylinder block heater.


Fuel returns to the fuel tank or the generator cannot start.

This is a common issue with newer engines that are not used regularly. To meet today's emission requirements, the tolerance within the fuel system is smaller, making the fuel system more susceptible to the influence of air that affects the generator's starting ability. This is not common in older generators. Older industrial diesel generator that experience this problem may leak in lines or check valves that do not properly hold fuel in the engine.


Non automatic control.

The industrial diesel generator has a control panel. This panel controls all aspects of the setup, operation and shutdown of the industrial diesel generator. It displays all key engine and alternator information and displays any 'faults' that caused it to shut down the generator. 99% of generator control service calls are 'non automatic' as a direct result of human error.


The obvious reason is that the main control switch has been placed in the "off/reset" position. The control switch may have several positions, such as "off/reset" and "cooling", which will cause the industrial diesel generator to fail to start in case of power failure. These locations should issue alarms.


Alarm not reset, circuit breaker open, switching device not reset, and emergency stop button activation are all examples of non automatic faults. Several generators have been set up to short-circuit the main circuit breaker during emergency shutdown. When the industrial diesel generator shuts itself down (for any reason), someone must physically reset the control panel to clear the alarm.


The engine ran out of fuel.

Mechanical fuel level gauges may not always be accurate. Unlike vehicles that move and use a higher percentage of their fuel tank capacity, the generator fuel tank does not move, resulting in fuel stagnation. Mechanical instruments may also be fixed in a certain position until vibration causes them to detach. Some industrial diesel generator are equipped with "low fuel level shutdown" or "critical fuel level shutdown". When the fuel is about to run out, the control panel will shut down the generator to prevent the fuel system from inhaling air.


The circuit breaker unrelated to the generator trips.

The service phone number is usually 'We have a power outage and the generator has not started'. Firstly, confirm that no one accidentally pressed the remote 'emergency power off switch'.


During a power outage, the status of the automatic transfer switch should be checked. ATS should have some type of light or display to display the switch position and signal source availability. If you do not know how to operate it correctly, do not attempt to manually operate the automatic transfer switch. The above are some common problems and solutions of diesel generator explained by Jiangsu Starlight Electricity Equipments Co.,Ltd.. If you have any problems with diesel generator, please contact Jiangsu Starlight Electricity Equipments Co.,Ltd. immediately. Looking forward to your inquiry, please send email to us for details sales@dieselgeneratortech.com.

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