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List of Quick Troubleshooting Solutions For Diesel Generators

Table of Contents

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.

WALT SILENT DIESEL GENERATOR 25/30KVA

GENSET

Low engine oil pressure

CausesRemedies
1. Oil pressure sensor is defectiveRepair or change the sensor
2. Lubricant oil is insufficientAdd lubricant oil
3. The oil hose has a leakTighten or change oil hose
4. The oil filter is cloggedChange the oil filter

High coolant temperature

CausesRemedies
1. Coolant is insufficientAdd coolant
2. The coolant pipe has a leakTighten or change coolant pipe
3. The fan belt is looseTighten the belt
4. The radiator core is cloggedClean radiator core
5. The coolant temperature sensor is defectiveRepair or change the sensor
6. The engine thermostat is defectiveRepair or change the thermostat

Low fuel level

CausesRemedies
1. Fuel is insufficientAdd fuel
2. Fuel tank leakRepair or change fuel tank
3. Fuel level sensor is defectiveRepair or change the sensor

Power drops after running a period

CausesRemedies
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 incorrectAdjust the ignition time as required

The ground metal part is electriferous

CausesRemedies
1. The ground connection is defectiveCheck ground wiring
2. Insulating resistance is too lowMeasure insulating resistance
UK DSE7420 DIESEL GENERATOR CONTROLLER

CONTROL SYSTEM

The main breaker cannot be turned on

CausesRemedies
1. The main breaker position rests on the position between ON and OFF improperlyFirst turn the breaker off, and then turn it on.
2. Short circuit on the loadCheck and repair the load circuit or change it

The control module cannot run

CausesRemedies
1. The control module cable is disconnected from the batteryConnect the module cable to the battery
2. Battery power is insufficientCharge the battery with the utility power.
3. The fuse is damagedChange the fuse
4. The control module is defectiveRepair or change the control module

Voltage drops quickly when connecting to the load

CausesRemedies
1. Loads total exceeds the rated currentDecrease the loads to meet the rated output
2. AVR of the alternator is defectiveCheck AVR and change it if necessary
3. Use the wrong frequencyAdjust the frequency to the load frequency

Frequency is stable, but voltage is unstable

CausesRemedies
1. Customer load is unstableCheck and adjust the customer load.

Voltage cannot go up to the rated value

CausesRemedies
1. AVR of the alternator is defectiveCheck AVR and change it if necessary
2. Frequency is lowAdjust frequency as required

Voltage exceeds the rated value

CausesRemedies
1. AVR of the alternator is defectiveCheck AVR and change it if necessary

The electric meter has not reading

CausesRemedies
1. The meter is defectiveCheck the meter, and change if necessary
2. The circuit is disconnected, or the terminal is looseFind the cut position and connect again
PERKINS ENGINE FOR DIESEL GENERATOR

DIESEL ENGINE

Engine cannot start

a. The starter motor cannot drive or the speed is low

CausesRemedies
1. The battery switch is offTurn the switch to on
2. Battery output is weakCharge the battery
3. Battery deterioratesChange the battery
4. The battery terminal is looseTighten the terminal

b. Starter motor drives, but the engine cannot start

CausesRemedies
1. Fuel is insufficientCheck fuel system, and add fuel if necessary
2. The fuel hose has a leakTighten or change fuel hose
3. Fuel filter is cloggedDrain water/sediment or change fuel filter
4. The gauze filter is cloggedClean or change gauze filter
5. Air is mixed in the fuel lineExtract the air

Engine starts but stalls at once

CausesRemedies
1. The fuel hose has a leakTighten or change fuel hose
2. The Fuel filter in the water/fuel separator is cloggedDrain water/sediment or change fuel filter
3. The gauze filter is cloggedClean or change the gauze filter
4. Lubricant oil is insufficientCheck the oil level, add oil as required
5. Air is mixed in the fuel lineExtract the air
6. Air filter element is clogged Clean or change the air filter element

Output is insufficient

CausesRemedies
1. Fuel is insufficientCheck the fuel system, and add fuel if necessary
2. Overheating of moving partsCheck to see if the lubricating oil filter is working properly
3. The air filter element is cloggedClean or change the air filter element
4. The injection pump is defectiveCheck the fuel injection pump element and delivery valve assembly, replace them if necessary

Muffler releases black smoke

CausesRemedies
1. Improper kind of fuel is usedSelect proper fuel
2. The air filter element is cloggedClean or change the air filter element
3. Loads total exceeds the rated currentAdjust the loads to meet the rated output
4. Accumulation of gas carbon is high on the exhaust pipes and mufflerClean out gas carbon

Muffler releases white smoke

CausesRemedies
1. The air filter element is cloggedClean or change air filter element
2. Lubricant oil is redundant and exceeds the limitedDrain the redundant oil
3. The piston ring(s) is (are) worn outChange piston ring(s)
4. Large clearance between cylinder and pistonChange the piston and cylinder

Muffler releases blue smoke

CausesRemedies
1. Fuel contains water or airCheck and change the fuel check and clean the fuel system
2. Injector nozzle atomizes badlyRepair or change injector nozzle
3. The cylinder and gasket are damagedRepair or change the cylinder and gasket

Engine overheats

CausesRemedies
1. Lubricant is insufficientCheck the oil level, add oil as required
2. The fan belt is broken or elongatedChange the belt or adjust the belt tension
3. Coolant insufficientAdd coolant
4. Radiator net or radiator fin clogged with dustClean the net or fin carefully
5. Improper kind of fuel is usedSelect proper fuel
6. The coolant temperature gauge or sensor is defectiveCheck the coolant temperature gauge or sensor and replace it if necessary
7. Overload runningReduce load
8. Radiator corn or coolant route is cloggedClean or replace radiator or defective parts
9. The fan, radiator cap, or radiator is defectiveReplace radiator or defective parts
10. The thermostat is defectiveCheck the thermostat and replace it if necessary

Engine shut-off failure

CausesRemedies
1. Electrical or manual fuel shutoff not closingVerify 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 intakeLocate and isolate the source of fumes.

Engine surges at idle

CausesRemedies
1. Air is mixed in the fuel lineExtract the air in the fuel system and check for suction leaks
2. Idle speed is set too lowCheck and adjust the low idle screw
3. Fuel filter is cloggedDrain water/sediment or change fuel filter as necessary
STAMFORD ALTERNATOR FOR DIESEL GENERATOR

ALTERNATOR

No voltage pr voltage is insufficient while the genset running

CausesRemedies
1. Winding is cutIntertwist the cut winding and weld firmly.
2. The wiring terminal is looseTighten the wiring terminal
3. The wiring terminal s defectiveClean or replace the defective terminal
4. Speed is too lowAdjust the speed and keep the rated speed

Voltage is unstable

CausesRemedies
1. Speed is unstableKeep the rated speed
2. AVR is defectiveCheck AVR, and change if necessary

Alternator overheats

CausesRemedies
1. Overload runningReduce load
2. The Vent-pipe inside the alternator is cloggedBlow and clean the inner

The voltage is too high

CausesRemedies
1. Speed is too highKeep the rated speed
2. AVR is defectiveCheck AVR, and change if necessary

Voltage is too low while running without a load

CausesRemedies
1. Speed is too lowKeep the rated speed
2. AVR is defectiveCheck AVR, and change if necessary

Voltage is correct without load, but too low under load

CausesRemedies
1. The speed setting is incorrectCheck and adjust the speed
2. Short circuit on the rotorCheck the resistance of the circuit
3. Armature of excitation is defectiveCheck the resistance of the circuit

Voltage disappears while running

CausesRemedies
1. Winding of magnetic field is cutCheck the cut winding, intertwist and weld firmly
2. The rotor of excitation is defectiveCheck the rotor, repair it, and change it if necessary
3. AVR is defectiveCheck AVR and change if necessary
VARTA BATTERY FOR DIESEL GENERATOR

BATTERY CHARGE

No charge current

CausesRemedies
1. The battery post is defectiveCheck and clean the post
2. The battery post is connected incorrectlyCheck the connection post
3. No mains supplyCheck the wiring to the charger from mains supply
4. The power fuse is burned outChange the fuse

Display nothing on the charge current meter

CausesRemedies
1. Charge current meter is defectiveMeasure the current with the standard amperemeter

The charge rate is too low

CausesRemedies
1. Mains supply power is lowCheck mains supply
2. The plug of the charger transformer does not match the mains supply voltageCheck the plug of the charger transformer
3. Battery post is looseTighten the battery post

The fuse of mains supply is burned out repeatedly

CausesRemedies
1. The power of the fuse does not matchChange the proper fuse
2. There is a short circuitCheck and connect all wiring

Charge clip heats

CausesRemedies
1. The battery post is defectiveCheck and clean the post
2. The bolt of the clip is looseClean and tighten the bolt

Battery voltage does not rise

CausesRemedies
1. Battery has deterioratedChange the battery
2. Battery has been damagedCheck 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)

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Ke Wong

Ke Wong

Hey, I’m Ke Wong joined WALT POWER in 2011. I spent a dozen years focused on generator set & load bank technology and solutions for the power & energy industry. WALT Power is a reliable & leading manufacturer & supplier in China, as a business director, I am so proud of our knowledge is more and more popular not only for engineers, and generator distributors but also for end-users. Hope you are enjoying our article, if any questions or comments welcome to send me sales at waltpower.com

Ke Wong

Hi, I’m the author of this post, and also the business director of WALT Power. I have been in this field for more than 17 years. If you want to know more about the generator set or services, please just feel free to contact me any time.

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