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Risks of Improper Load Operation of Diesel Generator Sets

Jul. 10, 2025

Many users of generator sets, in order to save costs when purchasing diesel generator sets, always calculate their power consumption loads to the maximum. If their 100% load reaches 400 KW, they only want to buy a diesel generator set with a power of 400 KW. This idea is not advisable. When a generator set operates at 100% load for a long time, it causes considerable damage to components such as the cylinder engine crankshaft, thus reducing the service life of the generator set. Some customers have low power consumption, but they purchase a diesel generator with a large power. For example, they only need a 50 - KW generator set but use one with a power of over 300 KW. This is also not advisable. It not only causes waste, increases fuel consumption and cost but also damages the unit.


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If the generator set operates at a low load for a long time, the water temperature fails to rise to the normal level. The viscosity of the engine oil is high, and the friction increases. The oil that should have burned in the cylinder forms a lacquer on the cylinder head gasket due to heating. If the low - load operation persists, blue smoke may appear. In this case, the lacquer on the surface of the cylinder head gasket needs to be removed, or the cylinder head gasket needs to be replaced.

 

The following faults may occur when a Yuchai diesel generator set operates at a low load for a long time:

 

1.Blue smoke emission

Poor sealing between the piston and the cylinder liner allows engine oil to leak upwards into the combustion chamber and burn, resulting in blue smoke in the exhaust.

 

2.Oil leakage

For a turbo - charged diesel engine, due to low - load or no - load operation, the boost pressure is low. This easily leads to a decline in the sealing effect of the turbocharger oil seal, allowing engine oil to leak into the boost chamber and enter the cylinder along with the intake air.

 

3.Carbon deposition

Part of the engine oil that leaks upwards into the cylinder participates in combustion, while part of it fails to burn completely. Carbon deposits form on the valves, intake ports, piston tops, piston rings, etc. Another part is discharged with the exhaust. As a result, engine oil gradually accumulates in the cylinder liner and the exhaust passage, also leading to carbon deposition.

 

4.Oil leakage

When the engine oil in the boost chamber of the turbocharger accumulates to a certain extent, it will leak from the joint surface of the turbocharger.

 

5.Component wear

Long - term low - load operation will more seriously lead to accelerated wear of moving parts, deterioration of the engine combustion environment, and other consequences that will advance the major overhaul period.

 

Dingbo Power has advanced testing equipment, modern production technology, professional manufacturing technology, perfect quality management system, and strong technical research and development capabilities. It can provide 3KW~2500KW various specifications of ordinary, automatic, four protection, automatic switching, low noise and mobile generator sets, high quality and low energy consumption to meet the diverse power needs of customers, and can also meet users with different voltages and different frequencies. It is required to create a parallel power supply system for multiple units. If you are interested in our product or any question on generator, welcome to send email to [email protected].

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