DIY repair of dsu

In detail: do-it-yourself repair of a diesel generator from a real master for the site my.housecope.com.

Diesel generators are indispensable in a wide variety of industries. Often, their operation is carried out in places where there are simply no official service centers. And the state of an industrial facility or other facility may depend on the high-quality and uninterrupted operation of the installation. If a person has a diesel generator, malfunctions, at least basic ones, he should know. He must also identify the most common causes of breakdowns and eliminate them.

The causes of malfunctions are revealed in the process of inspection and diagnostics. They are performed each time before starting the instrument. Read about how to properly start a diesel generator here.

First of all, the integrity of the case is checked. There should be no cracks or other mechanical problems in it. The case must be checked not only before starting the generator, but also if the device does not start at all.

If the hull is completely functional, you can turn on the diesel generator set. If the unit does not work well, but there is no external damage, the problem may be in the wiring. In particular, in the malfunction of the contacts or their absence.

If the diesel generator set, regardless of the power, does not produce voltage during operation, you need to check the contacts and brushes. If the check does not lead to the identification of the cause of the problem, the problem should be looked for in the voltage regulator and the poor condition of the winding.

There are also a number of mechanical reasons that affect the performance of a diesel generator. One of the reasons may be a malfunction of the bearing located in the cover of the device. The problem can be both in the part itself and in the cover. If the seat in the cover has exhausted its resource, the rotor "sits down" and touches the stator during rotation. The bearing and cover can be replaced by yourself.

Video (click to play).

With intensive operation of a diesel generator set, it is necessary to periodically replace the spark plugs. If a spark does not appear in the cylinder at a certain moment, the fuel will not ignite and the engine will not start. You can try cleaning the spark plug with rubbing alcohol and sandpaper.

During the operation of complex devices, various malfunctions and breakdowns are inevitable. There are a variety of factors that can cause problems. Among them are:

Untimely maintenance, operating errors caused by insufficient qualifications of users.
The use of low-quality fuel leads to a malfunction of the fuel systems of the device. As a result, the generator simply stops starting.
Overloads, also called "phase imbalance". The loads are unevenly distributed, causing the generator to overload.
The absence of protective hermetic casings, ventilation, thermal insulation and other systems that optimize the generator for operation in certain climatic conditions. High temperatures lead to overheating of the main components of the device. Low temperatures lead to freezing of the main components of the device. High humidity can cause fire to the wiring.

There are a number of signs by which you can determine the breakdown of the system and take action to eliminate it. It should be noted that one breakdown may be the result of another, more significant one. In this case, a complete overhaul of the diesel generator set may be required.

One of the most common breakdowns leading to costly and lengthy repairs is winding burnout. The main cause of this problem is electrical equipment being connected to the unit that is placing a load in excess of the generator's maximum.

DGS must be filled with high quality fuel, avoiding contamination or mixture with other brands. This is one of the main recommendations of most manufacturers.

Each unit must initially have all the necessary additional equipment, for example, protective covers. If previously used equipment is planned for installation, its operating functions may be reduced.

It is necessary to carry out routine maintenance of the device by qualified personnel. Not every owner of a diesel power plant can repair a diesel generator with their own hands, identify all faults and replace all necessary components.

The electrical part of the diesel generator is checked exclusively on de-energized equipment. If this is impossible for any reason, you need to contact a specialist.

Correct operation and timely replacement of consumables will prolong the trouble-free operation of the diesel power plant.

Diesel engine noise and black smoke

For diesel engines diesel power plant the image of noisy and smoky cars was fixed, which is generally correct.
The noise of a diesel engine is caused by the following: in the combustion chamber, during the injection of fuel and the beginning of its combustion, the pressure rises sharply, which causes this unpleasant noise to many. This noise is generally inevitable when the engine is running, but in recent years it has been significantly reduced: improvements in the design of the combustion chamber and injectors, as well as the use of noise shields with low-noise mufflers.

An increase in diesel noise is often caused by malfunctioning injectors.

Diesel smoke is associated with improper combustion of fuel. Unlike noise, this issue is almost completely resolved. While the engine is starting and warming up, a small amount of white or blue smoke is normal, but should not be present when operating under static load under normal conditions. Black smoke is usually caused by a lack of air: either the air filter is clogged or a large amount of fuel has been injected (with a significant increase in load).

Gasoline generators, even if they are made in China, very reliable with proper care... Nevertheless, during their operation, small problems can arise that can usually be quickly fixed with your own hands. Serious breakdowns with the knowledge of the owner of the device and the principle of operation of the generator will also not be able to disable it for a long time.

If you arrange possible malfunctions of the gas generator in a kind of rating, you get the following list:

Failure or contamination of the spark plug: difficult or impossible starting, unstable operation.
Clogged carburetor: difficult starting, excessive fuel consumption, unstable operation under constant load.
Failure of the ignition coil: no spark, inability to start.
Starter breakdowns: breakage, biting of the cable, destruction of the ratchet.
Violation of valve clearances: difficult starting, increased noise during operation.
Wear of brushes (on synchronous generators) - lack of output voltage.
Speed governor malfunction: floating engine speed, dips when changing the load.
Wear of the bearings of the crankshaft and the rotor of the generator - an increase in operating noise, oil leakage.
Wear of the cylinder, piston rings - difficult starting of a cold engine, excessive oil consumption.

It does not take into account breakdowns that result from a gross violation of the rules for operating the generator: for example, seizures on the crankshaft neck due to insufficient oil level, burnout of the generator windings or voltage converter (on inverter gas generators) with frequent overloads.

In fact, malfunctions of a gasoline generator can be divided into three groups: mechanical, electrical and fuel / ignition system malfunctions.

Difficulty starting the generator, which manifested itself suddenly and not accompanied by an increase in engine noise, is a clear sign of either deviations in the operation of the carburetor (too lean or rich mixture), or a faulty ignition system (weak or intermittent spark formation). Since the diagnostics of the state of these systems is interconnected, it is combined into one section.

Remove the spark plug and inspect the carbon deposits on the electrodes.

Dense and dry black carbon deposits - a sign of a rich mixture (the carburetor is faulty, the air filter is clogged);
Oily black carbon - a sign of severe wear of the piston rings, oil enters the combustion chamber;
White soot - a sign of running on a lean mixture, it is necessary to check the carburetor.
Brick brown carbon deposits - normal for carburetor engines.
Red, green-red carbon deposits - a consequence of working on low-quality fuel.

It is simple to check the performance of the ignition system itself because of its extreme simplicity: turn on the ignition, insert a known good spark plug into the plug cap and, putting it on the nearest metal part of the engine with its skirt, turn the recoil starter abruptly. If there is no spark, disconnect the ignition switch and the oil level sensor from the ignition coil in turn: if, when both elements are disconnected, there is still no spark, replace the ignition coil.

If the spark is present and strong enough (white or blue-white), remove the spark plug after several starting attempts. A candle filled with gasoline is a sign of an over-enrichment of the mixture, a dry one is a lack of fuel.

Sometimes, after long storage, the needle and the carburetor float stick and prevent gasoline from flowing inside. Several times sharply, but do not hit the float chamber lid very hard and start again.

The most common carburetor malfunction is contamination. The ingress of dirt into the air channels leads to an over-enrichment of the mixture, into the fuel jets - to a depletion. Dirt on the float shut-off needle leads to loss of tightness and overfilling of the float chamber, which will be immediately noticeable by the leakage of fuel from the carburetor.

Let's take a look at the carburetor maintenance using the example of a Honda GX engine installed - its design is typical of a gasoline generator.

Remove the float chamber cover (4). Wash it in gasoline or a carburetor spray cleaner - dirt and deposits accumulate at the bottom.
Proceed in the same way with the gas valve sump (22).
Check if the gas valve is blown in the "open" position.
Take out the float shaft (3), take out the float and the shut-off needle (2). Blow out the channel with air.
Blow out the fuel jet (25), emulsion tube (11) and all carburetor passages with an aerosol cleaner or compressed air.
Remove the adjusting screw (5), blow out its channel. Then screw it in until it stops and loosen, depending on the type of air filter, by 2 (foam, paper filters) - 2.5 turns (cyclone filters).
Assemble the carburetor.

The electrical system of gas generators is quite reliable. Most often, you can face two problems: lack of battery charging on generators with electric start or lack of voltage at the generator output.

The lack of battery charging is a consequence of the failure of the rectifier or low-voltage winding. It is easy to check this system with your own hands: connect a 12-volt light bulb in parallel with the low-voltage winding of the generator and start it. A lit light means that the generator itself is working properly, and it is necessary to replace the rectifier.
The absence of voltage at the generator output is most often the result of wear on the brushes. Remove them and assess the degree of wear, replace if necessary. If your generator is an inverter type, check if the voltage comes to the input of the converter by connecting a low-power 220 V lamp in parallel with it.

Video about the phased repair of the gas generator

One of the routine maintenance provided by the instruction manual for gas generators is the control and adjustment, if necessary, of the valve mechanism clearances. An increase in clearances above the norm will lead to a decrease in engine power, an increase in noise during operation. The most dangerous is a decrease in the gap, since it is not audible during operation, but the pinched valves, especially the exhaust, begin to burn rapidly. As a result, the engine starts to work unstably and, when the plate is burned out, it stops starting.Valve Adjustment Procedure pretty simple:

Remove all components that interfere with the removal of the engine valve cover.

Remove the spark plug.

Remove the valve cover.

Set the crankshaft to top dead center of the compression stroke by the mark on the flywheel (if any) or by controlling the movement of the piston through the spark plug hole. Do not confuse compression TDC (both valves are closed) with TDC issue (the outlet valve closes, the inlet valve opens).

Loosen the locknuts of the adjusting screws and, using a flat feeler inserted between the rocker arm and the end of the valve, set the clearances by turning the screw. Typically, a clearance of 0.2 mm is adopted for the outlet valve, and 0.15 for the inlet valve (check in the operating instructions).

Tighten the locknuts and turn the crankshaft twice to TDC. If everything is done correctly, at the next dead center both gaps will go away, after another turn they will take the set value. Increased gaps after the first revolution are a sign that they were adjusted at TDC of the exhaust stroke.

Assemble the generator.

Manual starter malfunctions - perhaps the most common mechanical problem... Either the cable breaks, or the starter refuses to rewind it due to a broken return spring, or the ratchet does not turn the crankshaft. Image - DIY repair of a dsu

Remove the starter by unscrewing the bolts around its casing. By unscrewing the screw (1), the ratchet can be removed. Check its cams (4) and return springs (5). Then carefully remove the pulley with the spring (7). Replace a broken cable or broken spring, whichever caused the repair.

When assembling the starter, care must be taken to ensure that the spring remains in engagement with the shroud and pulley while it is being reinstalled. The cable must be fully wound around the pulley. With the ratchet in place, check the cable travel and how the starter returns to its original position.

Review and repair of the Einhell STE800 gas generator

Sometimes it happens that the generator needs to be started urgently, and the recoil starter failed at that very moment. If necessary, there are several emergency start methods.The methods listed below unsafe! Remove the starter cover. A flywheel with a cooling impeller is located under it, which is pulled to the crankshaft by a nut. To make it spin, you can:

With a rope wrapped around the flywheel, use it in the same way as a recoil starter rope. Note that if it snags on the fan blades, the rope will turn into a whip whip when starting the motor, so be careful. Stand so that the rope cannot get caught in your hands or head.

Low-power engines can also be started manually: with the ignition off, turn the crankshaft several times, turning the pulley by hand in the desired direction. In this case, the gas valve must be open, and the shutter of the starting device must be closed. After that, turning on the ignition, bring the crankshaft to the compression TDC (you will feel an increase in the effort on the flywheel), and then turn the pulley with a sharp jerk so that the spark energy is enough to ignite the mixture.

A powerful cordless drill and an extension head from the tool kit are a good replacement for a quick electric starter. Clamp the extension in the chuck, put a head of a suitable size on it and unscrew the crankshaft by the flywheel nut.True, in this way it will be possible to start only a low-power generator - for a large-volume engine, the drill torque is not enough to turn it on the compression stroke.

A number of faults, alas, are quite difficult to fix with your own hands, without sufficient qualifications: for example, a faulty inverter converter or voltage regulator can only be repaired with a good understanding of the principle of operation and circuitry of such devices. Not every owner of a gas generator will take up the engine bulkhead, although this is not as difficult as it might seem.In this case, it is worth contacting a specialized repair shop. You can find out the coordinates of workshops in your city on the Internet or in shops selling gasoline-powered tools.In large cities like many workshops, here are just a small part of them:In our modern world, there are many machines, units and devices, without which not a single person can do. All the activities of people in any production, in construction, in military affairs and in everyday life are associated with the use of technology. Even the simplest mechanism requires energy and power sources to operate. And you know that it is not always and not everywhere there is an opportunity to connect to the main power grids. Often, objects are located separately and it is not rational to lead even temporary power supply lines to them. In this case, autonomous power sources are used - gasoline or diesel power generators.Generators with diesel internal combustion engines are most in demand. They are more economical and capable of delivering more power to drive a generator. The industry produces diesel generators of various capacities, from several kilowatts to hundreds. For domestic needs, it is enough to have a generator with a capacity of 2 to 4 kW.Such units are quite complex in the device, their repair requires certain knowledge and skills. Not everyone can do a complex repair of diesel generators on their own. It is always better to contact a specialist in a repair shop, where even a serious malfunction is guaranteed to be eliminated.However, it is not always possible to find a repair organization or the breakdown is insignificant and it will not be difficult to fix it yourself. To assess the possibilities of replacing a failed unit or part of a diesel generator, you should understand its structure well.Any generator driven by an internal combustion engine is capable of converting mechanical energy from the rotation of the motor shaft into electrical energy. Such installations can be used both as main power supplies and as a backup option. It is important to know that the automation of modern electric generators ensures that the engine starts when there is a power outage in the main line. It is not worth repairing powerful electric generators on your own. They are structurally complex and repair requires special equipment and tools. Image - DIY repair of a dsu

Small generators for household needs in summer cottages or in a country house can be repaired on their own. The mini power plant consists of the main components:

Diesel engine and systems to ensure its smooth operation.
Generator.
Automation and protection unit.
Fuel tank.
Frames.

The main cause of generator failure is engine failure. There can be many options for refusal. It is necessary to check all systems providing power, starting and stable operation of the diesel engine. The quality of the fuel and the fuel priming pump, the serviceability of the starter and the compression in each cylinder of the engine should be checked. Gasoline engines have a much larger list of possible malfunctions.

If the engine starts well and runs stably, but there is no output voltage, then the problem is with the generator.It is necessary to check the serviceability of the insulation of the wiring, the integrity and degree of wear of the brushes, the development of the collector lamellae.

Advice: if there is a short circuit of the winding or seizures and a large depletion of the collector lamellas, do not try to eliminate this malfunction yourself. In this case, special machines and equipment are needed. It is necessary to turn to professionals. It is difficult for an untrained person to determine what is the reason for the breakdown of an electric generator. If possible, it is always better to carry out troubleshooting and repair of the unit in a specialized workshop.

To start almost any mechanism, equipment and household appliances, electricity is required, which may not be available in some settlements and at remote construction sites. And in this case, a mobile power source comes to the rescue - a generator set. You can buy equipment in a construction equipment store, but it is much more profitable to use the service "power plant rental", Which has a lot of advantages.

You can determine the cause of the breakdown of the station by diagnostics at the service center or by self-examination. Some types of breakdowns can be identified and eliminated by hand:

Checking the integrity of the body, on which, if handled carelessly, cracks, dents, chips can occur. This inspection must be carried out regularly, especially if the station is installed outdoors.

If no mechanical damage is found, you need to check the wiring and connection contacts.

When the generator is running, there is sometimes not enough voltage, the cause may be damaged contacts, worn winding or malfunctions in the voltage regulator.

Unstable operation of the generator can be caused by wear on the bearing or seat in the cover. These parts can be purchased and replaced by hand.

If the unit is operated continuously, it is necessary to promptly clean or change the spark plugs, which ensure the ignition of the fuel.

Like any other equipment, the generator needs timely maintenance, which will help to avoid serious breakdowns and save the owner's finances. Among the main causes of breakdowns, the following are worth highlighting:

Violation of the operating rules specified in the manufacturer's technical passport.

The use of a low-quality and contaminated diesel engine will lead to clogged fuel hoses and breakdown of the entire system.

Overloading the generator when connecting a large number of devices will cause an emergency stop or poor performance.

Operation of the unit without a protective case, temperature stabilizers, control systems. If the generator is operated at high ambient temperatures, overheating of the internal components occurs. At low temperatures, the units of the unit freeze. High humidity conditions may cause short circuit and fire.

All these breakdowns can be eliminated at an early stage with routine preventive checks. Only observance of the instructions for the rules of operation will help to minimize the cost of repairs.

Did you find that your diesel generator is malfunctioning or has stopped starting altogether? First of all, it is necessary to inspect the equipment for visible problems. In this article, we will look at the main types of diesel generator sets (diesel generator sets) malfunctions, their causes, and also tell you how to eliminate them.

The first thing to do if a problem is found is to check the generator for external damage (which, by the way, is recommended before each start): if you see cracks, dents or other flaws on the body, then most likely the cause of the failure is mechanical damage. Also make sure that there are no foreign objects inside the appliance.

the generator does not start
does not give out tension
stalls during work
consumes more oil than it should
a loud knocking is heard during engine operation
strange color of exhaust gases (black, white-blue)

Let's consider each type in detail.

There may be several reasons:

Broken fuel pump: This is indicated by low or uneven fuel delivery.
The cold start device has broken. This is most likely due to fuel waxing, which usually occurs at cold temperatures. To prevent this from happening to your equipment, use seasonal fuel and do not use the appliance in cold weather.
Poor quality fuel or contaminated fuel. To avoid this, use only proven, clean, undiluted fuel: saving on fuel can lead to serious repair costs.
The starter is out of order, and as a result, its speed is insufficient. There are two reasons: a) the use of poor quality oil, b) a weak battery.

Attention! De-energize the equipment completely before checking any electrical part to avoid electric shock.

The diesel generator works, but does not produce voltage: it is possible that contacts are loose or missing or there is a problem in the brushes. Check their connection according to the instructions.

Another reason may be a problem in the voltage regulator or winding wear: inspect their condition.

In this case, there are 7 main reasons, some of which you can identify and eliminate yourself:

there is not enough fuel in the tank
air has entered the fuel
additional resistance in the fuel supply system or in the system for draining excess fuel into the tank, as well as in the intake or exhaust systems
dirty air filter
breakage of injectors
incorrect setting of idle speed

Check the oil system for leaks: oil may leak into other systems, for example, into the fuel system. To prevent leakage, use only quality oils.

Most often, knocking indicates wear or damage to the following parts:

injectors
valve springs
piston rings
cylinder-piston group
crankshaft bearing
camshaft

If the parts listed are OK, check the valve clearance, timing and injection timing settings. Is it okay too? Then the matter is in the presence of air in the fuel system or low-quality fuel.

Pay attention to the color of the diesel generator exhaust gas: black or blue-white indicates a problem. The most common cause is a dirty air filter. If you change the filter and the exhaust continues, the following options are possible:

malfunction, wear or breakdown of the following parts: injectors, high pressure fuel pump (high pressure fuel pump), glow plugs or relays of these candles (while smoke occurs only at startup), piston rings, cylinder-piston group, block gaskets
presence of additional resistance in the intake system
not adjusted: valve clearance, valve timing, injection moment
insufficient compression or turbo pressure
low-quality or inappropriate oil (engine) manufacturer's requirements

Remember that careful and correct use of your generator will extend its life.

If you find faults that you cannot fix on your own, call us at 8 (800) 555-06-29 or leave a request on the website and we will call you back within 20 minutes. Our experts will help you identify the cause of the malfunction and advise on the repair of diesel generator sets.

When you read this article, you will know: how to inspect a diesel generator before starting it, and how to independently identify and eliminate the main types of diesel generator malfunctions.

With long-term operation of generating sets, it becomes necessary to replace components. The power generator and motor are subject to wear.

Overhaul of the diesel generator may be required in the near future if:

The installation is operated in difficult conditions.
Alternator (alternator), engine are under uneven load.
Fuel of questionable quality is used.
Various overloads.

The operating mode of the installation is especially important. When the load is light, coking of the motor occurs.

Repair work includes a complex bulkhead of the device, replacement of key components (if necessary). Bearings are most susceptible to mechanical wear.

Due to the aggressive effects of high temperatures, moisture drops, the integrity of the protective coating of the winding is violated. Even minor damage will result in reduced resistance. The likelihood of a short circuit increases. If the operating time is more than 10,000 hours, the winding is varnished.

A common problem with generator sets is voltage regulator failure. With such a breakdown, it is impossible to repair the element - it must be replaced.

Sometimes overhaul is impossible due to critical wear of key systems. A complete replacement of the installation is a viable solution. Keep this in mind and do not take diesel generator breakdowns to extremes. In time, contact specialized service centers for help.

Overhaul is carried out:

According to the condition of the diesel generator. All preventive and repair work is carried out according to the frequency established in the documentation. The volume and duration of work is influenced by the current state of the unit.
Regulated - to the extent specified in the operating manual. The technical condition of the equipment does not matter.

Cases when equipment is repaired only due to technical breakdowns or is strictly regulated are very rare. Typically, repairing generators involves two methods at once. The most effective is the aggregate-nodal. Defective elements will be replaced with new or repaired parts.

Repair of power plants is carried out in accordance with the factory documentation.

Before the start of repair work, documentation is drawn up:

Specification.
Schedule. In what sequence will the work be carried out.
Deadlines.

The main document is a manual for the repair, operation of diesel generator sets. On its basis, the defect detection of parts after cleaning is carried out.

Overhaul of diesel generators consists of the following stages:

Diagnostics and analysis. Includes a thorough inspection of components, checking their performance. Takes the most time and is considered the most difficult. You cannot do without specialized equipment. The revealed defects are promptly eliminated, the worn out units are replaced with new ones.
Assembly. When all defects have been eliminated, the specialists proceed with the assembly. The mechanisms are thoroughly cleaned, treated with a special lubricant. Calibration is in progress to improve the efficiency of the generator. Particular attention is paid to small details. After all, even one mistake in the assembly can lead to more serious damage.
Functionality check. Finally, each node is checked using a computer and software. If even the slightest deviation is found, the generator is adjusted again. Then the station starts up to go through the final diagnostics.

An external examination is carried out to identify defects. It allows you to identify cracks and breaks, stripped threads. To detect hidden cracks, magnetic and ultrasonic flaw detection methods are used.
How to determine the condition of the winding? For this, special electronic devices and devices are used. Fault detection list is created. It is the basis for adjusting the repair schedule and its specifications. Interruptions and interturn short circuits are eliminated by rewinding. Problem areas are impregnated with electrical insulating varnish.
Defective assemblies and parts must be replaced. Sometimes they are machined.

The article considered the main stages of repairing diesel generators, a list of necessary documents, work schedule and the reasons for the failure of technical systems.

Remember that any problem is much easier to prevent. When maintenance is carried out efficiently and on time, even serious breakdowns can be completely ruled out.Anyone who operates diesel powered generator sets (diesel generators) knows that over time, the motor and power generator are subject to natural wear and tear. The operation of a diesel power plant is usually associated with a number of factors that accelerate these processes: intensive operation in difficult conditions, uneven loads on the engine and alternator, the use of inadequate fuel quality, untimely maintenance, overheating and overloading. All of these factors affect the service life of individual components.

Power generators.

Diesel engines DGU.

Diesel fuel system.

DPP automatics - power plant control.

Installing additional equipment and repair of diesel generators:

FG Wilson
Cummins
SDMO
Gesan
Pramac
Inmesol
Elcos
CTM, etc.

Our specialists will carry out diagnostics, as well as establish the malfunction and the degree of wear of parts of any diesel engines. After agreeing on the scope, timing and cost of repairs, we will be able to eliminate the detected faults in a short time. Our company offers original spare parts for your diesel generator or their analogs, while we carry out complex diesel engine repairs and the customer receives a turnkey solution without worrying about the details.Such repairs include a complete overhaul, replacement of many parts and key engine components. As a rule, we are talking about repairing the fuel system, block head, grinding shafts, cylinder boring and block repair, as well as welding. The need for overhaul arises in the event of a strong drop in power and compression, as well as when the engine is jammed. These are common occurrences when it comes to diesel generators with high operating time and, therefore, wear of key components.The main advantage of the overhaul of the motor is the possibility of optimal balancing of its operation. The bore of the cylinders gives them an ideal cylindrical shape, and the minimum difference in the weight of the pistons and connecting rods makes the engine more stable even in comparison with the factory assembly.Sometimes a diesel generator engine overhaul is impractical due to critical wear and tear of key systems. In this case, we will offer to make a complete replacement. Remember, the engine is the heart of your power plant. Do not go to extremes and seek help in time.High-quality engine maintenance, compliance with the maintenance schedule and operating conditions of the diesel generator prescribed by the manufacturer, timely troubleshooting guarantees the stable operation of your unit for the entire period of operation.During the operation of the DGS power generator, the thrust bearings are most susceptible to mechanical wear. During the repair process, they must be replaced. Over time, the protective lacquer coating of the stator and rotor windings also suffers. The integrity of the coating is compromised as a result of temperature effects and changes in humidity. Micro-damage to the lacquer coating causes a decrease in the insulation resistance and, in the event of an increase in the load on the generator, high humidity or temperature, can lead to a short circuit and breakdown - then the repair may already be impractical and a new one will have to be installed. When repairing a power plant with an operating time of more than 10,000 hours, all generator windings must be re-varnished. In addition, a common problem with diesel generators is the malfunction of the automatic voltage regulator, which usually, if it fails, must be replaced.Modern society cannot imagine life without a mass of necessary and useful devices, among which there are both household appliances and industrial units. The operation of each of them assumes the presence of a power source, and if the object is not connected to the main power grid, then this role is performed by autonomous power plants.However, such units are quite complex and it will be quite difficult to repair generators on their own. But sometimes there is no way to invite specialists and you have to do everything yourself. In order to perform such work correctly, you need to have certain knowledge and skills, therefore, before proceeding with the repair, you should carefully weigh the pros and cons.A diesel generator is a unit capable of converting mechanical energy generated by the rotation of the shaft of a diesel engine into electrical energy. Most often, it is a unit that can be used as a main power source, as well as a backup or emergency. Image - DIY repair of a dsu

The scope of application of such units is quite wide. The smallest models of diesel generators are designed to supply electricity to small objects such as holiday cottages. By the way, the repair of such a generator can be done by hand.

But there are generators on the market that have enough power to power household appliances not only in one cottage, but in a whole suburban village.

What components does a mini diesel power plant consist of and how does it work?

The main components of such an installation are:

Engine with systems that ensure its performance;
Alternator;
Frame;
Automation.

As for the principle of operation of the unit, it is quite simple. The expansion energy generated by the combustion of fuel is converted into mechanical energy by the crank mechanism. At the same time, the electromagnetic field excited by the rotor of the unit creates an electromotive force on the windings. This leads to the formation of an output voltage, which is supplied to potential consumers of electricity.

In order for the equipment to work properly, it is necessary to regularly conduct an independent inspection of it, and, if necessary, repair the generator with your own hands. In this case, you need to evaluate the appearance of the case. There should be no cracks or dents on it.

And only after making sure that the condition of the case is satisfactory, you can start the equipment. Usually this procedure is performed first if the unit does not work well or does not turn on at all.

But if the body is intact, and the generator does not work well, then it is necessary to assess the integrity of other components, in particular the wiring, and repair and service diesel generators. Even the poor condition of the contacts can negatively affect the operation of the equipment.

In the event of a situation related to the absence of voltage at the output, you need to check the serviceability of the brushes. But it should be remembered that inspection and repair of diesel generators and any electrical part of the equipment can only be carried out when it is de-energized.

But if the wiring, brushes, contacts are in good order, and there are problems in the operation of the generator, the voltage regulator may be broken. Checking its condition, the serviceability of the stator and rotor of the unit should also be assessed. It will be difficult to do such repair and maintenance of a diesel generator with your own hands.

However, mechanical damage to the bearing installed in the cover of the device may also be to blame. He could simply wear out. Moreover, the bearing can be replaced quite easily and you can cope with such a repair of a diesel unit yourself

It is quite difficult to immediately determine the reasons for equipment failure, because they can be not only simple, but also quite complex. Only a small part of faults can be diagnosed and eliminated on their own.And most breakdowns require not only professional knowledge to find them, but also special equipment to eliminate them for repairs.

Watching the video, expert advice:

To avoid serious consequences from poor-quality repairs, it is better to trust its specialists. Having extensive experience in repairing a diesel generator on their own, they will be able to conduct a thorough check and will not miss even the smallest nuances.If you yourself want to service and repair, please note that the technical documentation for each model indicates the inspection frequency recommended by the manufacturer.Engine overheating is considered to be one of the most serious problems in equipment operation. It occurs in any generators, regardless of whether a gasoline or diesel engine is installed in them.Most often, the cause of overheating lies in the incorrect installation of the unit. This is especially true for models equipped with containers or casings that make it difficult to repair a diesel generator.The next most important malfunction is excessive fuel consumption.It can occur for the following reasons:

Unstable operation at low speeds;

Poor starting at low temperatures.

But if you change the oils on time, you can avoid many troubles in the work and then you will not need to repair the diesel generator.Experts recommend replacing oils in diesel units using only high-quality materials and in a timely manner. Otherwise, the engine simply will not start or will constantly stall and the diesel generator will need to be repaired.Watching the video, generator maintenance: