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    How to troubleshoot a diesel generator

    How to troubleshoot a diesel generator

    Just as buying a generator can be complex in terms of decision-making and budgeting, and requires time and energy, maintenance has particular difficulties.

    Usually, most people entrust the maintenance and repair of their generators to specialists in the field of wrenches, but this is not always possible.

    Do not forget that diesel generators or gasoline generators, regardless of their type, are tools that are somewhat emergency in nature and are used in places and times where we see limited access.

    This means that your generator may have a problem but you do not have access to a repairman. Of course, this is just one aspect of the need to learn how to troubleshoot a diesel generator, there are dozens of reasons for this that need not be mentioned.

    Regardless of the reason why it is necessary to learn how to troubleshoot a diesel generator, we are here to review and explain in a limited volume of words, the main points that are needed to troubleshoot a diesel generator.

    So if you also have a history of buying and maintaining a diesel generator, join us at the end to understand how to troubleshoot a diesel generator.

    Troubleshooting a diesel generator is a differential or test-driven process



    This means that you have to act like a doctor in the process of troubleshooting a diesel generator and decide on the type of defect and the solution available by examining the symptoms. In this case, you should be careful that:

    A particular sign is not absolutely and definitively a sign of a particular defect. Sometimes by seeing a particular sign, two or more factors can be imagined for it.

    Conversely, a particular failure will not always lead to a particular sign. This is also effective in creating uncertainty in troubleshooting diesel generators.

    Considering the previous two points, you always face two distinct methods in troubleshooting a diesel generator:

    1) The first method is to try to narrow and narrow the circle of possible shortcomings by further investigation. Do this to the point where you end up with a specific problem.

    After this you can easily solve the problem depending on the solution it has.

    2) Try to address in order, all the problems that can lead to the existing symptoms in order of importance. You should follow this until the sign disappears.

    In the first method, the troubleshooting process will be more time consuming, but you will spend less money and energy on repairs, because by finding the exact problem, you will only implement the measures needed to solve the problem.

    But in the second method, you may not waste your time on troubleshooting, but you have to spend a lot of energy and money to solve problems.

    Sometimes you may experience the actual defect and problem that led to this symptom in the last step, which means that you have done several fruitless repairs and inspections.

    Ultimately, it is up to you to decide on your strategy for troubleshooting a diesel generator. The information provided by us in this memo is applicable to both methods.

    We categorized the signs of a defect in the diesel engine.

    We believe that the symptoms during the troubleshooting of a diesel generator will first be divided into two main categories:

    Signs related to the generator (electrical section)
    Signs related to the engine (driving force)

    Accordingly, the signs present during the troubleshooting of the diesel engine will be examined in two separate categories.

    Signs related to the generator (electrical section)



    In the following, we will examine the existing symptoms separately and try to mention the most common and logical reason for the occurrence of each symptom against it.

    The voltage of the device is not in the normal range (more or less): A fault in the voltage regulator (AVR) can be the source. It can also be due to the lack of adjustment of that part instead of a technical defect.


    The device has no output voltage at all: this can be a sign of various defects such as damage to the coil and generator core, damage to the voltage regulator, defects in the control and board circuits or damage to the diode bridge.


    The device loses load when outputting: it could be due to a defect in the generator winding or damaged parts such as the stator and rotor. Of course, there may be problems with the board and circuits.

    Apart from the above three signs, any signs including connection noise, any fluctuation in amperage and output voltage can be due to defects in fuel sensors, pumps, alternator failure, board failure and range components.

    In these cases, it is recommended that you stop using the device immediately.

    Signs related to the engine (driving force)



    According to the previous section, in this section, by mentioning the signs and their possible causes, we will welcome the review and continuation of the diesel engine electrician troubleshooting process:

    The diesel engine does not start or turns on hard: This can be caused by several distinct technical defects in the diesel generator. Fuel in the tank may be low in the first place.

    In the second step, the fuel transfer path or other air connection pipes may be blocked. The next problem that can lead to this symptom is clogging of the filter (fuel filter).


    Finally, if none of the above defects are evident, the health of the primary pump should be evaluated. It should be noted that if none of the above defects are clear and obvious, the problem can be solved only with a diagnostic device.

    The diesel engine will start but not at the right engine speed: this is due to a number of factors, including Farsunga gas shoulder jam, pickup sensor, governor or actuator defect, ECU misalignment or other mechanical defects that may occur without opening. Accurate verification of the root of the defect is not possible.

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