With the rapid development of the economy, electricity has become increasingly important and indispensable in daily life.
However, diesel generator sets are mechanical products after all.
As the use time increases, diesel generator sets may encounter some common problems during operation.
Users and technicians need to understand these common problems and know how to solve them quickly.
This article will introduce some common faults that may occur when using diesel generator sets and provide solutions.
From the five aspects of generator sets, control systems, diesel engines, AC brushless alternator, and batteries, users and technicians can take effective, correct, and fast measures to quickly troubleshoot when problems occur, ensuring that diesel generator sets can provide reliable power guarantees for a long time.
GENSET
Low engine oil pressure
| Causes | Remedies |
| 1. Oil pressure sensor is defective | Repair or change the sensor |
| 2. Lubricant oil is insufficient | Add lubricant oil |
| 3. The oil hose has a leak | Tighten or change oil hose |
| 4. The oil filter is clogged | Change the oil filter |
High coolant temperature
| Causes | Remedies |
| 1. Coolant is insufficient | Add coolant |
| 2. The coolant pipe has a leak | Tighten or change coolant pipe |
| 3. The fan belt is loose | Tighten the belt |
| 4. The radiator core is clogged | Clean radiator core |
| 5. The coolant temperature sensor is defective | Repair or change the sensor |
| 6. The engine thermostat is defective | Repair or change the thermostat |
Low fuel level
| Causes | Remedies |
| 1. Fuel is insufficient | Add fuel |
| 2. Fuel tank leak | Repair or change fuel tank |
| 3. Fuel level sensor is defective | Repair or change the sensor |
Power drops after running a period
| Causes | Remedies |
| 1. The air filter element is clogged, and air is insufficient. | Clean or change air filter element |
| 2. The fuel filter element is clogged, and air is insufficient. | Drain water/sediment of the Change fuel filter. |
| 3. Engine ignition time is incorrect | Adjust the ignition time as required |
The ground metal part is electriferous
| Causes | Remedies |
| 1. The ground connection is defective | Check ground wiring |
| 2. Insulating resistance is too low | Measure insulating resistance |
CONTROL SYSTEM
The main breaker cannot be turned on
| Causes | Remedies |
| 1. The main breaker position rests on the position between ON and OFF improperly | First turn the breaker off, and then turn it on. |
| 2. Short circuit on the load | Check and repair the load circuit or change it |
The control module cannot run
| Causes | Remedies |
| 1. The control module cable is disconnected from the battery | Connect the module cable to the battery |
| 2. Battery power is insufficient | Charge the battery with the utility power. |
| 3. The fuse is damaged | Change the fuse |
| 4. The control module is defective | Repair or change the control module |
Voltage drops quickly when connecting to the load
| Causes | Remedies |
| 1. Loads total exceeds the rated current | Decrease the loads to meet the rated output |
| 2. AVR of the alternator is defective | Check AVR and change it if necessary |
| 3. Use the wrong frequency | Adjust the frequency to the load frequency |
Frequency is stable, but voltage is unstable
| Causes | Remedies |
| 1. Customer load is unstable | Check and adjust the customer load. |
Voltage cannot go up to the rated value
| Causes | Remedies |
| 1. AVR of the alternator is defective | Check AVR and change it if necessary |
| 2. Frequency is low | Adjust frequency as required |
Voltage exceeds the rated value
| Causes | Remedies |
| 1. AVR of the alternator is defective | Check AVR and change it if necessary |
The electric meter has not reading
| Causes | Remedies |
| 1. The meter is defective | Check the meter, and change if necessary |
| 2. The circuit is disconnected, or the terminal is loose | Find the cut position and connect again |
DIESEL ENGINE
Engine cannot start
a. The starter motor cannot drive or the speed is low
| Causes | Remedies |
| 1. The battery switch is off | Turn the switch to on |
| 2. Battery output is weak | Charge the battery |
| 3. Battery deteriorates | Change the battery |
| 4. The battery terminal is loose | Tighten the terminal |
b. Starter motor drives, but the engine cannot start
| Causes | Remedies |
| 1. Fuel is insufficient | Check fuel system, and add fuel if necessary |
| 2. The fuel hose has a leak | Tighten or change fuel hose |
| 3. Fuel filter is clogged | Drain water/sediment or change fuel filter |
| 4. The gauze filter is clogged | Clean or change gauze filter |
| 5. Air is mixed in the fuel line | Extract the air |
Engine starts but stalls at once
| Causes | Remedies |
| 1. The fuel hose has a leak | Tighten or change fuel hose |
| 2. The Fuel filter in the water/fuel separator is clogged | Drain water/sediment or change fuel filter |
| 3. The gauze filter is clogged | Clean or change the gauze filter |
| 4. Lubricant oil is insufficient | Check the oil level, add oil as required |
| 5. Air is mixed in the fuel line | Extract the air |
| 6. Air filter element is clogged | Clean or change the air filter element |
Output is insufficient
| Causes | Remedies |
| 1. Fuel is insufficient | Check the fuel system, and add fuel if necessary |
| 2. Overheating of moving parts | Check to see if the lubricating oil filter is working properly |
| 3. The air filter element is clogged | Clean or change the air filter element |
| 4. The injection pump is defective | Check the fuel injection pump element and delivery valve assembly, replace them if necessary |
Muffler releases black smoke
| Causes | Remedies |
| 1. Improper kind of fuel is used | Select proper fuel |
| 2. The air filter element is clogged | Clean or change the air filter element |
| 3. Loads total exceeds the rated current | Adjust the loads to meet the rated output |
| 4. Accumulation of gas carbon is high on the exhaust pipes and muffler | Clean out gas carbon |
Muffler releases white smoke
| Causes | Remedies |
| 1. The air filter element is clogged | Clean or change air filter element |
| 2. Lubricant oil is redundant and exceeds the limited | Drain the redundant oil |
| 3. The piston ring(s) is (are) worn out | Change piston ring(s) |
| 4. Large clearance between cylinder and piston | Change the piston and cylinder |
Muffler releases blue smoke
| Causes | Remedies |
| 1. Fuel contains water or air | Check and change the fuel check and clean the fuel system |
| 2. Injector nozzle atomizes badly | Repair or change injector nozzle |
| 3. The cylinder and gasket are damaged | Repair or change the cylinder and gasket |
Engine overheats
| Causes | Remedies |
| 1. Lubricant is insufficient | Check the oil level, add oil as required |
| 2. The fan belt is broken or elongated | Change the belt or adjust the belt tension |
| 3. Coolant insufficient | Add coolant |
| 4. Radiator net or radiator fin clogged with dust | Clean the net or fin carefully |
| 5. Improper kind of fuel is used | Select proper fuel |
| 6. The coolant temperature gauge or sensor is defective | Check the coolant temperature gauge or sensor and replace it if necessary |
| 7. Overload running | Reduce load |
| 8. Radiator corn or coolant route is clogged | Clean or replace radiator or defective parts |
| 9. The fan, radiator cap, or radiator is defective | Replace radiator or defective parts |
| 10. The thermostat is defective | Check the thermostat and replace it if necessary |
Engine shut-off failure
| Causes | Remedies |
| 1. Electrical or manual fuel shutoff not closing | Verify the solenoid is not being energized by a short in the wring. Check the linkage to the shutoff lever for binding. Check for the ability of the spring in the solenoid to move the lever to the shutoff position. |
| 2. Fumes generated while the engine is running are drawn into the air intake | Locate and isolate the source of fumes. |
Engine surges at idle
| Causes | Remedies |
| 1. Air is mixed in the fuel line | Extract the air in the fuel system and check for suction leaks |
| 2. Idle speed is set too low | Check and adjust the low idle screw |
| 3. Fuel filter is clogged | Drain water/sediment or change fuel filter as necessary |
ALTERNATOR
No voltage pr voltage is insufficient while the genset running
| Causes | Remedies |
| 1. Winding is cut | Intertwist the cut winding and weld firmly. |
| 2. The wiring terminal is loose | Tighten the wiring terminal |
| 3. The wiring terminal s defective | Clean or replace the defective terminal |
| 4. Speed is too low | Adjust the speed and keep the rated speed |
Voltage is unstable
| Causes | Remedies |
| 1. Speed is unstable | Keep the rated speed |
| 2. AVR is defective | Check AVR, and change if necessary |
Alternator overheats
| Causes | Remedies |
| 1. Overload running | Reduce load |
| 2. The Vent-pipe inside the alternator is clogged | Blow and clean the inner |
The voltage is too high
| Causes | Remedies |
| 1. Speed is too high | Keep the rated speed |
| 2. AVR is defective | Check AVR, and change if necessary |
Voltage is too low while running without a load
| Causes | Remedies |
| 1. Speed is too low | Keep the rated speed |
| 2. AVR is defective | Check AVR, and change if necessary |
Voltage is correct without load, but too low under load
| Causes | Remedies |
| 1. The speed setting is incorrect | Check and adjust the speed |
| 2. Short circuit on the rotor | Check the resistance of the circuit |
| 3. Armature of excitation is defective | Check the resistance of the circuit |
Voltage disappears while running
| Causes | Remedies |
| 1. Winding of magnetic field is cut | Check the cut winding, intertwist and weld firmly |
| 2. The rotor of excitation is defective | Check the rotor, repair it, and change it if necessary |
| 3. AVR is defective | Check AVR and change if necessary |
BATTERY CHARGE
No charge current
| Causes | Remedies |
| 1. The battery post is defective | Check and clean the post |
| 2. The battery post is connected incorrectly | Check the connection post |
| 3. No mains supply | Check the wiring to the charger from mains supply |
| 4. The power fuse is burned out | Change the fuse |
Display nothing on the charge current meter
| Causes | Remedies |
| 1. Charge current meter is defective | Measure the current with the standard amperemeter |
The charge rate is too low
| Causes | Remedies |
| 1. Mains supply power is low | Check mains supply |
| 2. The plug of the charger transformer does not match the mains supply voltage | Check the plug of the charger transformer |
| 3. Battery post is loose | Tighten the battery post |
The fuse of mains supply is burned out repeatedly
| Causes | Remedies |
| 1. The power of the fuse does not match | Change the proper fuse |
| 2. There is a short circuit | Check and connect all wiring |
Charge clip heats
| Causes | Remedies |
| 1. The battery post is defective | Check and clean the post |
| 2. The bolt of the clip is loose | Clean and tighten the bolt |
Battery voltage does not rise
| Causes | Remedies |
| 1. Battery has deteriorated | Change the battery |
| 2. Battery has been damaged | Check the battery, and change it if necessary |
CONCLUSION
Regular monitoring and timely maintenance can ensure a smooth and uninterrupted power supply.
Experienced professional engineers can always keep the generator set in good working condition and reduce risks and extend the life of the generator.
With the importance and growing demand for electricity in modern society, it is very important to choose a reliable diesel generator set with a low failure rate.
And reduce the property loss caused by power outages at critical moments.
Buying And Technical Contact
You can contact us in many ways:
You can go to our website (URL: https://waltpower.com/contact/) and drop us a message.
You can email us: sales@waltpower.com
Our Contact is: +8618717996108 (WhatsApp)
