Diesel Generator Alarms and Trips

Diesel generator set is a power generation equipment, it uses diesel oil, driven by a diesel engine
to generate electricity. The whole set of diesel generator is generally composed of diesel engine,
generator, control cabinet, fuel tank, storage battery for starting and control, protection device,
emergency cabinet and other components.

Following alarms,

1. HT Water Temperature High and High

2. Low Lube Oil Pressure
3. Fuel Oil Pressure Low
4. Low Lube oil level in Sump
5. Over speed Alarm
6. Exhaust Temperature Deviation or High
7. Pre-Lubrication Pressure Less
8. Oil Mist Detector High

Diesel Generator Alarms and Trips

1- HT Water Temperature High

Reasons:

1. Cooling Water Coming Is of High temperature

2. Engine is suddenly overloaded
3. Air in the system
4. (Sensor or controller) is incorrect
Actions

1. Check if LT temperature is all right

2. Exhaust temperature of individual unit to be checked
3. Vent the system
4. Check sensor and Controller

Reasons Generators Shutdown on High Temperature and how to fix them?

On most generators, you will find two different water/coolant temperature detection devices
fitted, a switch and a sender.
The Switch, often supplied by the engine manufacturer is used to shut down the engine in the
event of the coolant becoming too hot. On fault, it closes to earth.
The sender is used to give a reading of engine temperature on the panel but can also be used by a
controller to shut down at a specified temperature.  The resistance or voltage (depending on the
sender fitted) changes depending on the coolant temperature. It is normal not to get a reading
below about 60 degrees (the same as your car).
 So why might the generator be shutting down?
The generators coolant is too hot.
Coolant heats up as the engine is running; the coolant is pumped (by the 'water pump') through
the radiator where the engine fan blows ambient air through the radiators matrix to reduce the
coolants temperature.
Check the temperature of the coolant.
! Remember if you take off the radiator cap it may be pressurized and very hot! Take
appropriate precautions! The coolant may also be very hot if it has overheated, and steam
may escape when opening the cap.
If the coolant is too hot the coolant switch may have shown a fault (normally by closing to earth)
or coolant sender has indicated a reading (either resistance or voltage) that is too high - in both
these instances the controller will take action to shut down the set. The coolant could be too hot
because:
1. The load on the engine is too high, meaning the coolant cannot be cooled fast enough;
this leads to the coolant getting hotter and hotter until the coolant switch closes on
fault causing shutdown. (or the controller shutting it down by reading the sender). - In
this case reduce the load on the generator.
2. The radiator matrix has gathered dust / oil and the air cannot pass in sufficient
quantity, leading to the same effect as per 1. above. In this case get a professional to
clear your radiator.
3. The inside of the radiator has corroded and the pipes that carry the coolant have
clogged. This can happen due to using the incorrect coolant / water mixture, or
incorrect type of coolant, or failing to change your coolant at the specified intervals.
This leads to the same effect as 1. above also. In this case you will need the radiator
power flushing - but you might need a new radiator.
4. The 'water pump' may have failed, leading to the coolant not flowing around the
system. In this case you would require a new water pump.
 Note: In this instance the coolant in the radiator may still be cool, as it is unable
to be pumped from the engine to the radiator.
5. The thermostat has failed; the thermostat opens as the engine gets warm to allow the
air to flow around the radiator. If the thermostat has failed, you will need to fit a new
thermostat. Note: In this instance the coolant in the radiator may still be cold, as it
is unable to flow from the engine to the radiator.
6. If you have recently filled the unit, there could be an airlock in the system, meaning
the amount of coolant in the system is too low and getting too hot. In this case add
more coolant, after releasing the air lock.
7. It could be the unit is shutting down too early if it is set to shut down on the sender.
Because the sender sends a resistive or voltage value to the controller, the controller
 then converts this into a temperature. Check the controller set point is correctly for the
engine.

If the coolant is not too hot, it could be because:

1. The thermostat has failed; the thermostat opens as the engine gets warm to allow the
air to flow around the radiator. If the thermostat has failed, you will need to fit a new
thermostat.
2. The 'water pump' may have failed, leading to the coolant not flowing around the
system. In this case you would require a new water pump.
3. The coolant switch has shown a fault incorrectly to the controller (normally by closing
to earth).
 Check for a closed circuit to see if the switch is opening / closing correctly and
for broken wires (a coolant switch wire that has shorted to earth will also cause
this fault.
 Something conductive touching the switch and the engines frame at the same
time would also display the same symptom.
 The coolant around the switch is too hot (whereas it is cool in the radiator) this
indicates either a water pump or thermostat failure.
4. The coolant sender is displaying a value that is too high. There are a few possibilities
for this:
 The sensor is not in the coolant and is therefore reading the temperature of the
air (underfilled / air lock). Take it out, make sure it is in coolant and reseat
it. The coolant may also be very hot if it has overheated, and steam may
escape when removing the sender.
 The coolant around the sensor is too hot (whereas it is cool in the radiator) this
indicates either a water pump or thermostat failure.
 The electrical resistance or voltage of the circuit it not corrects - the sensor
may have failed or there may be a fault in the circuit. Measure and test it
independently of the controller and confirm it is working to its specification.

2- Low Lube Oil Pressure

Reasons:

Pump Failure

1. Wrong Sensor Value, Gauge Malfunction, or controller.

2. Oil pressure control valve of engine.
3. Oil Filters
4. Oil Cooler Dirty
Actions: Check above for the problem and rectify the same.
Is diesel generator reporting low oil pressure? By means of a warning light or a message on the
controller display.

Possible reasons for low oil pressure warnings in a diesel generator:

 Oil Level Too Low– This is the most obvious thing to check initially. If there’s not
enough oil in the engine this may be down to evaporation or increased oil consumption.
Due to the age of the generator, but visually check for leaks and replace/tighten
components if necessary. Consult your generator manufacturer or manual to ensure that
you use the correct type and quantity of oil. Your generator engineer will top-up the oil
during each service. It’s good practice to regularly check levels in between such visits.
 Faulty Oil Pump– A worn pump may be leaking oil or may not be able to create
sufficient pressure, in which case repair or replacement should be carried out.
 Clogged Oil Filters– Check the oil filters and replace if necessary.
 Faulty Pressure Gauge or Switch – If you’ve checked all the above and everything
seems fine, it may be that the pressure gauge is at fault. Use another pressure gauge to get
a second opinion, and if the oil pressure reading is normal then replace the generator’s
pressure gauge.
Do not ignore a low oil pressure warning.  As a lack of lubrication can cause serious internal
damage to your generator, leading to an expensive repair bill. Regular checks and planned
preventative service and maintenance can prevent this. As soon as you are aware of this issue
then take immediate steps to ensure that it’s rectified as a matter of urgency.

3- Fuel Oil Pressure Low

Reasons:

1. Fuel Oil Filter Dirty

2. fuel oil supply pump malfunction
3. Fuel oil inlet valve throttled or not fully open
Sensor Malfunction.

Actions: Rectify the above reasons. Also, when you changeover to other fuel oil grade line DO,
the filters tend to get dirty very fast. So, a low fuel oil pressure alarm comes in.

Cause and Solutions for Low Generator Oil Pressure: Low oil pressure is one of the common
faults of generator. The method of quick troubleshooting is helpful to solve the problem in
time. Below Jiangsu Starlight Electricity Equipment Co.,Ltd will teach you how to accurately
find the cause of generator engine oil pressure problem.
1. Check the oil pressure display device
 
Use replacement method to check, that is to replace the oil pressure gauge or sensor. If the oil
pressure display is normal after replacement, the oil pressure display device has trouble. If the oil
pressure indicator is normal, the oil pressure is reduced, and the fault is in the lubricating part,
the following method should be used to judge.

Check oil temperature

If the oil temperature is too low and the oil pressure is also low. But when the temperature
rises, the oil pressure is still normal, it is due to the excessive oil and the bad oil passage. For
example, the original impurity of the oil filter is affected by the original impurity and the oil
pressure is reduced, but it is still within the specified range when the oil viscosity is too large.
The oil pressure is too low, and the oil pressure is too low; some diesel engine oil pressure
display device is located at the end of the lubricating oil road. When the filter is difficult, the oil
pressure is reduced. When the value is lower than the specified value, the oil pressure is too low.
Then, the oil should be further examined. The reasons for the thickening (the selection of the oil
number and the season are suitable, the oil deterioration, etc.) and the blockage of the oil channel
(such as the filter, filter, air cooled radiator, etc.) should be eliminated.
 
If the oil pressure drops when the oil temperature is high, it indicates that the oil viscosity is too
small, or friction parts have large clearance or leakage. The reasons for the decrease of viscosity
should be found out further (such as improper selection of oil grades, poor quality of oil, poor
viscosity and temperature stability, or the mixing of diesel and oil to dilute the oil). It is
necessary to find out whether there is an oil leak or if the clearance of the matching parts (such
as crankshaft and bearing, connecting bar shaft diameter, and bearing) is too large, and the
engine has been used for a long time, which should be dealt with pertinently.

2. Judging according to the service life of the equipment

If the oil pressure is too low and the failure occurs during the running period, most of the faults
are suspected to be acrobatic clogging filters such as metal chips in the machine parts or molding
sand in casting, or if the pipes are bent and shrunken. Or improper assembly of oil leakage (such
as too large bearing clearance, pipe joints or joint plane sealing) and so on.
3. Diagnosis by sudden and progressive reduction in oil pressure
If the oil pressure drops suddenly, indicate that the pipe or gasket ruptures, should identify and
eliminate the leak.
If the oil pressure decreases gradually with the prolongation of service time, check whether the
oil pressure is clogged, worn, oil deterioration, etc., find out the cause and remove it.

If the oil pressure decreases gradually with the prolongation of service time, check whether the
oil pressure is clogged, worn, oil deterioration, etc., find out the cause and remove it. In general,
a single cause may have an effect on oil pressure, but not too low. The condition of oil storage
and deterioration should be checked before diagnosis. If both do not meet the requirements, this
is one of the reasons for the decrease in oil pressure. The filter should be removed again to check
the clogging of mechanical impurities, if there is a clear clogging, it is the fault. It is also
possible to check the fit clearance between the crankshaft and the associated bearing. If the wear
is increased, it is also one of the reasons for the reduction of the oil pressure.
 
4. Check pressure limiting valve
 
Remove the pressure limiting valve after cleaning and reload and adjust (increase spring
elasticity), if the oil pressure increases, it is the fault that the oil pressure is too low.

According to the above inspection method, you can find the source of the problem, the right
remedy. It should be noted that if the generator is close to the wear and tear period, it is most
likely due to increased leakage of the lubricating system and low oil pressure caused by the
clogging of the filter or pipeline, the generator needs to be overhauled in time.

4- Low Lube oil level in Sump

Reasons:

1. Sump Level Low

2. Too much consumption of lube oil
3. Oil Cooler Leakage
4. Leakage

Actions: If the alarms come frequently that means, engine is consuming too much of lube oil.
This means that the piston rings are leaking, and lube oil is getting burned away.

Reasons for Low Oil Pressure in a Diesel Engine

Before any inspection begins it is important to take a few precautions before tearing into the
engine. Remember to keep all parts clean and free of contaminants. Any dirt or debris that gets
into the engine can cause wear, misalignment of critical parts or clog various oil passageways.
Use of an oil pressure gauge will determine if the problem is in the top end or bottom end of the
engine.

It is also important to note to contain all fluids when inspecting the parts of the engine. Try your
best to maintain critical fluid levels as best you can to ensure parts of the engine are not
contaminated. Also dispose of all fluids according to local and federal regulations.
1. Engine Oil Level Is Low:
The first place to check if the oil level is low is the crankcase. The most common problem is that
there is simply not enough oil in the engine. The oil level may simply be below the oil pump
supply tube. Simply put, this will cause the oil pump not to work as it does not have the ability to
pump oil to the engine components. The solution is to simply add the correct level of oil to the
engine. Make sure to refer to “Refer to Operation and Maintenance Manual” for the
recommended oil for your engine.
2. Engine Oil Is Contaminated:
Fuel or coolant in the oil will cause low engine oil pressure. Excess fluids in the oil
consequently will cause high oil levels in the crankcase. High oil levels in the crankcase will
generally always point to excessive fluid leaking somewhere else in the engine. Common
contaminants include diesel fuel, coolant, or water. The engine builder will then have to
determine the source of the fluid leak and make appropriate repairs. After the source of the
contamination is found and fixed the oil should be drained and refilled with the approved grade
of oil. It is also recommended to change the oil filter. Sometimes the low oil pressure is due to
something so small as a clogged oil filter.

Caterpillar oil filters are built specifically for Caterpillar engines. That being said there are
aftermarket oil filters that will do the job just fine. OEM dealers will recommend the use of
propriety oil filters stating unauthorized filters will allow larger particles into the engine
potentially causing damage to the bearings, crankcase etc… but most of that is simply untrue.
Aftermarket filters are built to the exact same standards at the OEM ones.

3. Engine Oil Bypass Valves Are Open:

If the engine oil bypass valves are set in the “Open” position, it can result in lower engine oil
pressure. The cause of open bypass valves is usually debris in the engine oil. Debris could be dirt
or metal shavings from internal damage from one of the internal hard parts (camshaft, crankshaft,
pistons etc…) The solution to this issue is to remove each oil bypass valve and clean out any dirt
or debris. It is also wise to clean each bypass valve bore. Once the bypass valves are cleaned the
oil should be changed as well as the oil filter.
4. Oil Lines or Oil Passages Are Not Working:
An oil line or oil passage that is open, broken or disconnected will cause low engine oil pressure.
The engine builder should check each oil passage for debris and wear. Sometimes oil galleries
can be out of alignment where the holes are not lined up correctly to allow normal oil flow.
Check that the oil lines are hooked up properly and that there is not a tear in the line.

An open lubrication system could also be caused by a piston cooling nozzle that is missing or
damaged. Piston cooling nozzles direct engine oil towards the bottom of the piston to cool the
piston. These nozzles also provide lubrication for the piston pin. Incorrect installation, restriction
of normal movement or breakage of the piston cooling nozzles could result in the seizure of the
piston itself.
5. Restriction in the Oil Suction Tube - Low Oil Pressure:
There is an inlet screen in the oil suction tube which can get clogged or damaged. This restriction
will cause cavitation and a loss of engine oil pressure. The solution is to check the inlet screen on
the oil pickup tube and remove any material that may be restricting oil flow. Low engine oil
pressure may also come from the oil pickup tube not sitting properly and drawing in air vs. oil.
Check the joints of the oil pickup tube for cracks, alignment, or a damaged O-Ring seal. The best
way gain access to the oil pickup tube is by removing the oil pan.

6. Problems with the Oil Pump:

Any sort of air leakage in the supply side of the oil pump will also cause cavitation (back
pressure) and loss of oil pressure. The engine builder should check the supply side of the oil
pump and make any necessary repairs.

The other common issue with the oil pump is excess wear to the gears. Gears that are out of
tolerance will not have enough power to create suction. The engine builder must repair or replace
the gears in the oil pump or purchase a new pump.
7. Improper Bearing Clearance:
If the engine bearings have excessive clearance it could result in low oil pressure. Check the
internal engine components where bearings are present to make sure they are in spec. If the
bearings are worn it is advised to replace the bearings or make necessary repairs to the
components.
5- Over speed Trip
Reasons:

1. Governor or Controller failure or faulty

2. Fuel rack for a unit is stuck
3. Sudden change in the load
Actions: Sudden change of load occurs like when the engine is loaded with high load suddenly.

Diesel generator sets are mainly used in power supply of various prime, standby, and emergency
power sources, also can be used in electric power supply for electric propulsion system. Its
importance is self-evident. When we use diesel generator set, it may be a overspeed problem, this
is a special fault, it will not only cause serious damage to spare parts, but also may endanger
personal safety. What is the cause of overspeed and how to resolve the problem?
1. Fault phenomenon of diesel generator overspeed
Under normal operation, the engine speed suddenly rises, so that the engine speeds up beyond
the rated speed and loses control, and emits a huge roar, the exhaust pipe emits a lot of black
smoke or blue smoke.
2. Cause of failure
The fundamental cause of diesel engine overspeed is that diesel engine loses or changes its speed
regulation characteristics. Faults of fuel injection pump and governor, such as stagnation or
looseness of relevant components, will cause excessive oil supply and loss of normal speed
regulation characteristics, while the combustion chamber entering additional diesel or oil will
change the speed regulation characteristics of diesel engine.

1) Faults of injection pump and speed regulator

A. When assembling and repairing, impact the plunger, oil outlet valve seat of fuel injection
pump, too much tightening torque will cause the deformation of plunger sleeve, impurities
entering into the clearance of plunger pair, too thin gasket on the positioning bolt of plunger
sleeve or too long bolt, which will cause the plunger of fuel injection pump to rotate
inadequately or be stuck in the position of large oil supply.
B. Loosening of fixing screw for adjusting gear ring of fuel injection pump plunger which causes
injection pump plunger loss control.

C. The ball head of the plunger adjusting arm or the gear rod adjusting arm of the fuel injection
pump does not enter the adjusting fork groove, so that the plunger is in the position of large oil
supply.

D. Accelerating pedal pull rod or oil supply adjusting gear rod and the movable part of governor
are stuck, and oil quantity adjusting gear rod and speed adjusting pull rod are out of joint;

E. The excessive lubrication oil, too viscous or too dirty in the governor cause the weight of the
governor cannot be thrown out in time when the speed rises, which causes the pull rod or the
gear rod to lose control of the governor;

F. Full speed governor cannot be thrown away because of skew of flying ball seat or abrasion of
inclined sliding groove of thrust plate transmission plate, which increases the sliding resistance
of flying ball.

G. The springs of injectors are too weak or broken, which results in too low injection pressure
and excessive fuel consumption in cylinders.

H. Flying ball Pin Shaft of governor broken off and flying ball flying off.

The above reasons make the speed of diesel engine increase, while the "speed characteristic" of
plunger fuel injection pump increases the fuel supply with the increase of the speed, which leads
to the vicious circle between the speed and the fuel supply, resulting in the occurrence of
overspeed accidents.

2) Additional fuel enters the combustion chamber

A. Engine oil level too high causes excessive oil to rush into the cylinder then enter the
combustion chamber to burn.

B. Serious wear of piston rings and excessive clearance of cylinder wall lead to a large amount of
oil entering combustion chamber to burn;

C. Excessive gap between air door and its catheter coordination is too large, which cases oil for
valve distribution chamber enter into combustion chamber to burn.

D. After cleaned air cleaner, the excessive residual gasoline makes the higher concentration
gasoline vapor enter the combustion chamber to burn.

E. A diesel engine with a supercharger enters the combustion chamber to burn because of the
damage to the oil seal of the supercharger.

F. The solenoid valve of the cryogenic starter leaks oil, which causes excess diesel oil to enter
the combustion chamber to burn.
G. Horizontal diesel engine inclines seriously, causing oil to flow into the valve chamber and be
sucked into the combustion chamber to burn.

3. Solution to overspeed fault of diesel generator set

1) Forced stoppage
Once the diesel engine has overspeed, the following measures should be taken promptly to force
the diesel engine to stop immediately
A. Quickly retrieve the accelerating pedal to the stop position.

B. For fuel injection pumps with exposed rods or toothed rods, the rods should be quickly pulled
back to the stop position.

C. For diesel engines equipped with decompression devices, the decompression handle should be
quickly pulled to the decompression position, so that the diesel engine shuts down because of the
uncompressed gas.

D. If a closing device is installed on the intake pipe, the extinguishing device shall be closed
immediately or the intake port of the air filter shall be blocked quickly with cloth, and the fuel
tank switch shall be closed to cut off the gas and oil circuit, stop the oil supply and gas supply,
and cause the cylinder to be suffocated and shut down.

E. Put the transmission into the high gear in time, while trampling the brake pedal to the bottom,
and slowly lift the clutch pedal, so that the engine is forced to extinguish.
2)After the generator set stop working, to make a definite diagnose

A. If the acceleration pedal is raised rapidly, the engine will not continue to rise after reaching
the maximum speed, the fault is the acceleration pedal rod or arm is jammed;

B. If the acceleration pedal is raised rapidly, the engine speed cannot be reduced or extinguished
immediately, usually the governor is out of order;

C. If the acceleration pedal is picked up, the engine speed continues to rise, indicating that the
fuel injection pump has a fault;

D. If the fuel supply system is good, it means that there is extra fuel or oil entering the cylinder.
All above problems should be maintained by professional personnel.

6- Exhaust temperature deviation Alarm

Reasons:

1. Fuel rack position for unit is wrongly calibrated

2. Fuel Pump Defective
3. Fuel injector Defective
4. Engine is not balanced
5. Sensor is touching the engine body.
6. Engine is overloaded
Actions: Do the performance check of the engine. And check the PV diagrams. If something is
wrong than, either the injector or fuel pump is faulty.

Balancing of power from all units to be done at the load instructed by the engine maker and fuel
racks to be adjusted as per that.

during daily rounds of the engine room, checking the exhaust temperature is a normal and most
important observation. it tells the working condition of the engine, and any possible deviation
may point towards possible problem in the system.

if the exhaust temperature increases then it may be due to following problems: -

a) when exhaust temperature of only one-unit increases: -
 tappet clearance increases.
 exhaust manifold got chock.
 increase in piston clearance leading to blow past in decrease in compression pressure.
hence incomplete combustion and increase in exhaust temperature.
 leaky exhaust valve
 leaky fuel injector
 fuel pump timing to be checked.
 in case of main engine, scavenge fire can also lead to high exhaust temperature.
 fuel pump rack linkage more inside than normal
b) when exhaust temperature of all unit increases: -
 turbocharger fouling.
 air filter of turbocharger fouled.
 air cooler chocked on water side.
 air side fouled of air cooler.
 fuel oil temperature decreases leading to problem in atomization.
 governor problem.

7- Pre-Lubrication Pressure Low

Reasons:

1. Pre-Lubrication Pump is not working properly

2. Clogged Strainer for pump
3. Faulty pressure sensor or gauge

Air in the system

Actions: Check the system for air and release it by slightly opening the fitting to the sensor and
let it release.
 8- Oil Mist High Alarm

Reasons:

1. Lubrication failure inside the rotating machinery, leading to the activation of oil mist
detector alarm
2. Purifier oil inlet temperature kept too high, leading to accumulation of mist inside the
crankcase as oil is heated too much.
3. Dirty Sensor for the oil mist detector or control panel failure.

Action: If you get oil mist level high level, the engine will slow down and shut down. Open the
crankcase doors to check the signs of hotspots.

Keep the purifier inlet temperature as per the manufacturer.

Regularly clean the oil mist detector head for avoiding the false alarms.

Generator Alarms and Trips- Trips:

Note: Most of the alarms won’t trip the generator, but there are some major alarms which will
cause the generator to trip, and they are as follows:

 Low Lube Oil Pressure

When this alarm is activated, generator will shut down immediately.

 High HT Cooling Water Temperature

This alarm too leads to shutdown of the generator immediately.

 Over speed Trip

If the generator senses the over speed, it will suddenly reduce the speed and shutdown.

This was all from the article on generator alarms and trips.
What is the reason of faults for low voltage shutdown?

1.Mechanical speed regulation of diesel engine

Diesel engine speed regulation includes electronic speed regulation and mechanical speed
regulation. If it is mechanical speed regulation, there is an oil pump mechanism on the diesel
engine to control the oil volume and oil circuit, it seems called common rail oil pump. There is a
pull rod on it to control the oil quantity. It is called speed regulating pull rod temporarily. A
speed limiting (high-speed) top rod and speed regulating top rod are distributed on both sides of
the speed regulating pull rod, and the low pressure will be reported after starting and running for
20s. If the voltage and frequency is still not in normal value, the reason may be speed. We can
try to adjust regulation top rod. If diesel genset has faults, there must be a main fault. After
resolving the main fault, all problems will be resolved.

2.Voltage sample line loose

If the line is loose, there will be no voltage.

3.Residual magnetism

If the generator has no residual magnetism, the voltage system of the generator cannot be built at
the beginning. For this problem, we need to know how much voltage the excitation output of the
AVR regulator plate of the generator is, and then connect the corresponding voltage source on
the excitation output line for magnetization (the voltage type should be corresponding, and the
polarity should not be reversed).

4.Grounding fault

If the outgoing line is three-phase grounded, the voltage and current are very low. At this time, it
is mainly to check whether the grounding discharge device (such as the grounding knife) is
closed or grounded.

5.Regulating plate fault

Due to the change of environmental factors, the parameters of AVR pressure regulating plate are
no longer applicable and need to be readjusted. This kind of problem will not appear in non-
parallel diesel gensets. Because the parameters of the pressure regulating plate are fixed value
(400V), we can't adjust them generally. Only the unit used for parallel operation may have this
problem. Because AVR voltage regulator is regulated according to the voltage of main bus
during parallel operation,
it is not unchangeable. At this time, there is a voltage regulating signal sent to AVR voltage
regulator by parallel operation device. In this case, either check whether the voltage regulating
signal is connected wrongly or try to use electronic control (parallel operation device, voltage
regulator, etc.) to readjust the voltage quickly when starting up.

 
6.The varistor or rectifier bridge diode on the generator winding is damaged
The function of varistor is to turn on the varistor in case of over-voltage fault to reduce voltage.
If the varistor is broken down or turned on for other reasons, it can be imagined that the voltage
must be very low. The rectifier bridge has 6 diodes. The set DC power supply is used to supply
the regulator and excitation devices. If the rectifier bridge diodes are damaged, the function of
the regulator and excitation devices will be greatly weakened buckle.
What Causes High Voltage in Diesel Generators? What Can
We Do to Prevent Generator from Being Over Voltage?
1.Voltage regulator failure
The failure of the voltage regulator should be the primary consideration. A faulty voltage
regulator may cause over voltage or under voltage.
2.Unstable diesel engine speed
The speed of a diesel engine affects the voltage. If the RPM is unstable, it will result in an
equally unstable voltage output. The noise of a diesel generator with unstable RPM will
fluctuate due to dirty or clogged fuel pipe, dirty fuel filters, and insufficient fuel, etc. High
RPM will result in high generator voltage and the reason may be due to the generator
frequency (hertz) is not set accurately.
3.Cable Failure
Worn faulty output cables, broken sheaths and peeling of the insulation can
increase electrical resistance that can cause short circuits and lead to voltage output spikes.
If the cables appear to be intact, make sure that the connections and terminals are not
loosen or damaged. Otherwise, they will also affect the voltage output.
4.Voltage measurement before connecting the loading
Some might think that the diesel generator has an over voltage problem is because the
voltage is not measured before the load was connected. But the output voltage of a diesel
generator without loading is usually higher than the output voltage of a diesel generator
with loading.
To determine if the voltage is too high, you need to look at the generator's design threshold.
If the measured output voltage does not exceed the generator's design threshold, there is
nothing to worry about. The voltage of the diesel generator may peak when with loading
but will gradually decrease when the load is being removed.
How to control the high voltage of the diesel generator?
1.Replace damaged voltage regulator
If the voltage regulator is defective, it must be replaced. A defective regulator may cause
serious damage to the function of the diesel generator.
2.Clean the fuel filter
If there is a problem with RPM, clean the fuel filter and increase the fuel level. Keep fuel lines
clear and unobstructed. In many cases, diesel generators run too high simply because the
diesel generator settings are not properly configured.
In addition, by adjusting the throttle can raise or lower the RPM, and by lowering the RPM
will at the same time lowering the voltage. Use a voltmeter to measure the voltage output
when adjusting the throttle. This will allow the RPM to be maintained within the desired
range. The engine RPM affects the governor, and the governor affects the volume of
fuel input.
A damaged governor can cause the same speed instability and thus increase the output
voltage. Therefore, proper maintenance must be performed to prevent deterioration of the
valve function of the governor and actuator valve.
3.Replacement of worn cables
Replace damaged or worn cables. Each connection should be checked to ensure it is secure
and safe and damaged connections and terminals in the diesel generator should be
inspected.
What happens if the diesel generator voltage is too high?
High voltage in diesel generators can damage sensitive electronic components and
equipment. The excessive heat generated by high voltage can damage circuit boards within
the appliance. Over-voltage can cause immediate or long-term damage. If you would like
more information about diesel generators or are ready to purchase a diesel generator,
please contact Tide power as we have a wide selection of generator sets available and can
meet any power needs. 

How to Deal with Low Voltage of Diesel Generator

1. If the contact surface of generator brush is too small and the voltage caused by poor
contact is too low, it is necessary to check whether it is caused by the commutator
surface, if it is, at low speed, to polish the commutator surface with sand cloth, or to
adjust the spring pressure.

 2. When the generator set is used, the voltage is too low. It may also be that the
diesel engine speed is too low. In this case, you need to check the diesel engine speed.
You only need to adjust the prime mover speed to the rated value.

3. During the process of using diesel generator set, the unit voltage is too low because
the resistance of the excitation circuit is too large, and the resistance of the magnetic
field rheostat is reduced to increase the excitation current. For semiconductor excitation
generator, check if the additional winding connector is broken or connected incorrectly.

4, check whether the generator exciter brush is in the neutral line position. It is
recommended to adjust the electric brush to the correct position, or to replace the
brush to solve the problem of low voltage.

5. Check if there is a short circuit or ground fault in the stator winding or excitation
winding of the generator set, and check the fault and clear faults in time.

6. Some rectifier diodes are broken down. It is necessary to deal with in time. Check
and replace the broken diodes.

The Cause Of Overspeed In A Diesel Generator

Diesel generator sets are mainly used in power supply of various prime, standby and
emergency power sources, also can be used in electric power supply for electric
propulsion system. Its importance is self-evident. When we use diesel generator set, it
maybe a overspeed problem, this is a special fault, it will not only cause serious
damage to spare parts, but also may endanger personal safety. What is the cause of
overspeed and how to resolve the problem?
1. Fault phenomenon of diesel generator overspeed

Under normal operation, the engine speed suddenly rises, so that the engine speeds up
beyond the rated speed and loses control, and emits a huge roar, the exhaust pipe
emits a lot of black smoke or blue smoke.

2. Cause of failure

The fundamental cause of diesel engine overspeed is that diesel engine loses or
changes its speed regulation characteristics. Faults of fuel injection pump and governor,
such as stagnation or looseness of relevant components, will cause excessive oil supply
and loss of normal speed regulation characteristics, while the combustion chamber
entering additional diesel or oil will change the speed regulation characteristics of diesel
engine.
1) Faults of injection pump and speed regulator

A. When assembling and repairing, impact the plunger, oil outlet valve seat of fuel
injection pump, too much tightening torque will cause the deformation of plunger
sleeve, impurities entering into the clearance of plunger pair, too thin gasket on the
positioning bolt of plunger sleeve or too long bolt, which will cause the plunger of fuel
injection pump to rotate inadequately or be stuck in the position of large oil supply;

B. Loosening of fixing screw for adjusting gear ring of fuel injection pump plunger which
causes injection pump plunger loss control;

C. The ball head of the plunger adjusting arm or the gear rod adjusting arm of the fuel
injection pump does not enter the adjusting fork groove, so that the plunger is in the
position of large oil supply;

D. Accelerating pedal pull rod or oil supply adjusting gear rod and the movable part of
governor are stuck, and oil quantity adjusting gear rod and speed adjusting pull rod are
out of joint;

E. The excessive lubrication oil, too viscous or too dirty in the governor cause the
weight of the governor can not be thrown out in time when the speed rises, which
causes the pull rod or the gear rod to lose control of the governor;

F. Full speed governor can not be thrown away because of skew of flying ball seat or
abrasion of inclined sliding groove of thrust plate transmission plate, which increases
the sliding resistance of flying ball;

G. The springs of injectors are too weak or broken, which results in too low injection
pressure and excessive fuel consumption in cylinders;

H. Flying ball Pin Shaft of governor broken off and flying ball flying off.

The above reasons make the speed of diesel engine increase, while the "speed
characteristic" of plunger fuel injection pump increases the fuel supply with the increase
of the speed, which leads to the vicious circle between the speed and the fuel supply,
resulting in the occurrence of overspeed accidents.

2) Additional fuel enters the combustion chamber

A. Engine oil level too high causes excessive oil to rush into the cylinder then enter the
combustion chamber to burn;

B. Serious wear of piston rings and excessive clearance of cylinder wall lead to a large
amount of oil entering combustion chamber to burn;

C. Excessive gap between air door and its catheter coordination is too large, which
cases oil for valve distribution chamber enter into combustion chamber to burn;

D. After cleaned air cleaner, the excessive residual gasoline makes the higher
concentration gasoline vapor enter the combustion chamber to burn;

E. A diesel engine with a supercharger enters the combustion chamber to burn because
of the damage to the oil seal of the supercharger;

F. The solenoid valve of the cryogenic starter leaks oil, which causes excess diesel oil to
enter the combustion chamber to burn;
G. Horizontal diesel engine inclines seriously, causing oil to flow into the valve chamber
and be sucked into the combustion chamber to burn.
3. Solution to overspeed fault of diesel generator set

1) Forced stoppage
Once the diesel engine has overspeed, the following measures should be taken
promptly to force the diesel engine to stop immediately
A. Quickly retrieve the accelerating pedal to the stop position;

B. For fuel injection pumps with exposed rods or toothed rods, the rods should be
quickly pulled back to the stop position;

C. For diesel engines equipped with decompression devices, the decompression handle
should be quickly pulled to the decompression position, so that the diesel engine shuts
down because of the uncompressed gas;

D. If a closing device is installed on the intake pipe, the extinguishing device shall be
closed immediately or the intake port of the air filter shall be blocked quickly with cloth,
and the fuel tank switch shall be closed to cut off the gas and oil circuit, stop the oil
supply and gas supply, and cause the cylinder to be suffocated and shut down;

E. Put the transmission into the high gear in time, while trampling the brake pedal to
the bottom, and slowly lift the clutch pedal, so that the engine is forced to extinguish.

2)After the generator set stop working, to make a definite diagnose

A. If the acceleration pedal is raised rapidly, the engine will not continue to rise after
reaching the maximum speed, the fault is the acceleration pedal rod or arm is jammed;

B. If the acceleration pedal is raised rapidly, the engine speed can not be reduced or
extinguished immediately, usually the governor is out of order;

C. If the acceleration pedal is picked up, the engine speed continues to rise, indicating
that the fuel injection pump has a fault;
D. If the fuel supply system is good, it means that there is extra fuel or oil entering the
cylinder.
All above problems should be maintained by professional personnel. 

Fault Fault characteristics and causes Elimination method

Pressure sensor broken Replace the pressure sensor
Poor quality of lubricating oil Replace the lubricating oil
Oil filter is dirty Replace the oil filter
Oil pressure alarm shutdown
Pressure valve failure Repair or replace pressure valves
Oil pump failure Replace the oil pump
Insufficient oil Add oil
High water temperature alarm Add cooling water, the cooling
Insufficient cooling water water must be distilled water
and stop
Water temperature sensor is Replace the water temperature
broken sensor
Engine cannot start Tubing has air Check, exhaust air
Tank valve is not open Open the oil tank valve
Oil tank without oil Add fuel
 Poor fuel quality Replace the fuel
Starter motor failure Replace the starting motor
Insufficient battery capacity Charge the battery
Battery terminal oxidation, poor Rust removal, fasten battery
contact connection bolt
High pressure oil pump failure Repair or replace the oil pump
Air filter is blocked Replace or clean air filter
The atomization of injector is Check the nozzle couplings for
Exhaust white smoke poor, there is oil drop grinding or replacement, and re-
phenomenon, and the injection adjust the injection pressure to
pressure is insufficient. the specified range
 Fault characteristics and causes Elimination method
Fault

Fuel line, fuel filter into air or Remove air or replace fuel filter
blocked cartridge
Fuel injection pump does not Check for repair or replacement
atomize oil of coupling parts
The generator body is overheated, Check the cooler and radiator to
Diesel engine power
the ambient temperature is too remove scale; check if the pipe
high, the   temperature of the oil diameter is too small. If the
and cooling water is high, and the ambient temperature is too high,
discharge temperature is also the ventilation should be
greatly increased. improved to improve the cooling
effect.
The transmission gear is worn,
and the tooth gap is too large; the
Adjust the backlash and replace
front cover   emits an abnormal
the gear according to the wear
sound, and when the engine
condition
suddenly drops, the impact sound
can be heard.
Inlet   and the exhaust valve
There is abnormal noise when the
clearance is too large, and a loud
diesel engine is running. Recalibrate the valve clearance
rhythmic noise is   heard at the
cylinder head.
There is no oil between the rocker
arm adjusting screw and the
spherical seat of the push rod. Add oil
The "squeak" of dry friction is
heard at the cylinder.
Air filter blocked; intake air Check and clean the air filter
blocked
Exhaust black smoke
The fuel supply of each cylinder Adjust the fuel injection pump
is uneven.