Most of time, diesel generator runs abnormally because of battery long time no maintenance or the deviation between components . In reality, it can be back to normal as long as you make a little adjustment. Therefore, we should have the ability to deal with the faults.
Generators are crucial for providing an ‘insurance policy’ in case of power failures and offer some peace of mind. But the last thing anyone wants is for a generator to fail as well! That’s why it is so important for generators to undergo regular maintenance to ensure all their systems are in good repair and functioning properly.
Here are some of the top 10 reasons that generators fail—and some tips for what you can do to address the risk in the meantime.
1. Problems with the Battery System
Based on our experience, close to half of all emergency generator failures are caused by problems with the battery. Routine battery maintenance is important for good performance. Connections need to be cleaned and tightened. You should also note the service life of your batteries and replace them proactively. Towards the end of its life, a battery will provide closer to 80% of its designated capacity. Periodically checking the circuit breaker on the battery charger is also recommended, as this is a frequent cause of battery failures.
2. Controls Not Set for Automatic Operation
Although it may seem obvious, one issue that we see frequently is the master controls for the generator not being set for “Auto” (automatic operation). This can also occur when the emergency stop button is pressed. Building the habit of double-checking the master control set is a great way to prevent failures.
3. Overheating from Cooling System Failures
Cooling systems failures are most commonly caused by worn-out hoses and drive belts. Both should be regularly inspected to ensure they are working properly and set at the correct tension. Another component that needs inspection is the radiator core. Radiator cores can become plugged, either from dust and debris or as a result of corrosion and dirty coolant. Monitor the coolant to assure cleanliness and correct chemical balance, then perform a visual check to ensure plugging does not cause overheating.
4. Water Contamination or Lack of Fuel
Don’t let water get into your fuel supply! Water or moisture in fuel can easily damage diesel engines or impact their overall performance. Keep your fuel tanks topped up and use fuel stabilizers to protect the diesel from water contamination.Take a fuel sample regularly and inspect for discoloration or abnormal smell. Remember to monitor the fuel levels consistently as well. It’s another obvious tip, but being proactive about topping off your tanks will ensure you do not find yourself in a panicked situation as your generator is about to shut down!
5. Switchgear Problems
Switchgear or automatic transfer switches (ATS’s) contain moving parts that need to be inspected during maintenance. Issues with switchgear are commonly the result of some kind of mechanical failure. Parts can seize if they are left in one position for too long, so monthly testing is recommended. Check for loose connections or a buildup of dirt, dust and other debris. This will help ensure everything is working smoothly.
For the failure of diesel generator, first you should have a adjustment and check whether it is helpful. Then what problems should we pay attention to when making a adjustment?
Regulator adjustment: If the faults like charging ammeter pointer stops movement, charging ammeter is too large or small occur during the process of using diesel generator, it needs a regulator to adjust. If battery charging current is too large, it will shorten the service life. If it is too small, it can't give battery charged on time. If the charging ammeter shows the charging current is too large when diesel generator works, you should adjust the current limiting spring of regulator to shorten the spring. The current should be reduced. Or vice versa. In the process of adjusting, not too hard, light touching until it meets the requirements.
Oil pressure adjustment: In general, diesel generator has two lubrication methods. One is pressure lubrication, the other is splash lubrication. Diesel generator lubrication quality is closely connected with oil pressure. Therefore, when the diesel generator is at work, the oil pressure must be controlled within the valid range.
Diesel generator decompression adjustment: In the process of using diesel generator in winter, it is hard to start because of the cold weather or battery shortage. To make the diesel generator set gets started, you can depend on the diesel generator inlet valve decompression way to reduce the compression radio and improve the starting resistance.
Fan belt adjustment: The tightness of the diesel generator fan belt should be just right. If the belt is too tight, it will exacerbate the wear to the direct generator bearings, water pump bearings and fan bearings. If it is too loose, it will cause insufficient fan air volume, influence the cooling effect of the cooling water, reduce the water pump flow, which can't reach the usage requirement. So the fan belt should be regulated according to the usage requirements.
The above processing methods to deal with generator failures are shared by Jiangsu Starlight Electricity Equipments Co.,Ltd, a professional manufacturer of diesel generator. Hope it can help you.
Power failures can happen for a number of reasons: bad weather, an overloaded power station, or damage to transmission lines. Whatever the reason, many businesses and government organizations put backup generators in place to ensure normal operation can continue while the issue is resolved. Depending on the situation, loss of power can be incredibly detrimental to service delivery or productivity.
We supply multiple brands of generator set, such as: Cummins, Volvo, Deutz, Doosan Daewoo, MTU, Ricardo, Perkins, Shangchai, Weichai, Yuchai etc. The style of genset is varied, such as: container genset, trailer genset, portable trailer genset, soundproof genset, low noise genset, and silent genset, etc. Besides, we also supply design and construction of the noise reduction project up to the customer's requirements.
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