When our generator is used for a long time, it will
undoubtedly result in all kinds of problems that lead to generator failure. If
your generator fails to start, you can analyze the causes from the following factors.
1. Oil
leaks
Diesel engine generators are designed to operate with a
load — most effectively in the 70% to 80% range of rated output. When
generators operate considerably below the rated output level, the engine can
start to over-fuel or “wet stack” which causes damage the engine.
Wet stacking is
the accumulation of carbon particles, unburned fuel, lube oil, condensed water
and acids in the exhaust system and is caused by low combustion chamber
temperature. When a diesel engine wet stacks, the engine will need to be
cleaned up by loading the unit for a few hours and burning off excess fuel.
The most common failure for diesel generator is battery failure. Battery failure is commonly the result of low electrolyte levels. To solve the problem, use the battery with sufficient power, or increase the battery to use in parallel. Replace the new start-up battery if necessary. Most often, many battery problems are caused by dirty and loose connections. So the battery maintenance is very necessary.
Attention: the cable connections need to be regularly cleaned and tightened. Besides, you should monitor the charge rates from month to month that will help prevent the failure.
3. Air
in the fuel system
This is a common problem with newer generators that are
not run on a regular basis. Closer tolerances within the fuel systems to meet
today's emission requirements make fuel systems more susceptible to air
affecting start up. This is not as common with older generators — many of which
may have a leak in a line or check valves that are not properly holding the
fuel in the engine.
4. Low coolant levels
This is caused by internal or external leak.
Internally plugged radiator cores will also cause low coolant level shutdowns. When the generator is under load, the thermostats open completely and the radiator cannot allow the proper amount of flow through the core. The coolant has to go somewhere, so it purges through the overflow line.
5. Ran
out of fuel
Mechanical fuel level gouges may not always be accurate.
Unlike a vehicle that is moving and using a higher percentage of its tank's
capacity, a generator tank has no movement, causing the fuel to become
stagnant. Mechanical gouges may also stick in a position until vibrations break
them free.
Water or moisture in fuel can be damaging to diesel engines because the water properties create advanced ignition and accelerated
detonation. If you use fuel polishing as an alternative to cleaning your fuel,
check with your vendor to see if its fuel is affected by the chemicals; fuel
polishing may not be able to remove water.
Maintenance tips:
Please note that a generator is a
mechanical and electrical device that will require service to maintain proper
function. Therefore, routine maintenance is very important.
1. Radiator fins should be checked on
a monthly basis and cleared of all dirt and debris.
2. Inspect the water pumps for signs
of water, bulges, cracking, and leaks.
3. Change fuel filters every 200 to
250 hours, depending on environmental conditions and how clean it is.
4. Make sure the battery and charger
connections are tight and clean any corrosion off the terminals. Be sure the
battery charger must be turned off before working on the battery or the
starter.
5. Check the engine for leaks and
wear.
6. Check the engine belts for wear,
cracking, or looseness.
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