DIY diesel generator repair

In detail: DIY repair of diesel generators 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 every 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.

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.

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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.

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 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 step-by-step 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 diesel generator repair

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 reassembling the starter, care must be taken to ensure that the spring remains in engagement with the shroud and pulley during installation. 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 gas generator Einhell STE800

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 using 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:Even the most expensive equipment cannot be operated indefinitely: any mechanism has its own resource of work. Sooner or later, the service life of a part will come to an end and it will need to be replaced. Therefore, systems of measures have been developed to detect and eliminate possible malfunctions for any equipment.The existence of service centers greatly facilitates these procedures, however, owners of generating equipment often have to carry out them on their own, starting with visual assessment and diagnostics, and ending with the repair of a failed unit.This procedure is carried out before each start-up of the generator and significantly reduces the likelihood of post-start accidents.

Diagnostics of the case for cracks and other mechanical damage. If its integrity is not in doubt, you can proceed to the next stage.

Inspection of the engine and hoses. Make sure the oil lines and gaskets are intact.

Checking fuel and oil levels.

Checking the integrity of cables, outlets and extension cords.

Next, you can start the engine and check the performance of the unit. Make sure that there is no abnormal noise during operation and that the vibration level is correct.

It is necessary to check whether there is a voltage at the output of the generator and whether it is correct. All performance data displayed on the dashboard indicators are checked.

If an external examination revealed any malfunctions, you can try to fix them yourself or invite a specialist. Below are tables with typical breakdowns that can be easily eliminated without assistance.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 diesel generator repair

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.

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Power plants are widely used both in everyday life and in small business and in industry. In this regard, such a service as the rental of generators has recently become especially popular. However, constantly using this device, one should not forget about regular maintenance, during which a specialist will be able to identify the breakdown and repair the device in time.

Correct repair of a diesel generator

If you are the owner of a diesel generator, or you have a rental of diesel power plants, then you should take care in advance and study some of the technical features of the device. This will allow you, if necessary, to independently carry out simple repairs without calling the specialists of the official service. Buy in advance the necessary parts and tools that you may need during the repair. However, in the event of a serious breakdown, it is recommended to contact professional repairmen, since only they have the necessary equipment, experience and qualifications. Remember that a specialist must necessarily be familiar with the operating instructions, know the timing of maintenance and be able to replace consumables. Do not entrust this kind of work to garage "craftsmen". Diesel generators are very demanding, so any careless actions can lead to more serious consequences. And by contacting an official service center, you can count on certain guarantees.

Correct repair of a diesel power plant begins, however strange it may sound, with the purchase or conclusion of a lease agreement. Be sure to make sure that all the necessary items are filled in the warranty card for the equipment. Sign a maintenance contract, as it can save you from possible breakdown and later save both time and money. Make sure that the specialist who will carry out maintenance and repairs has all the necessary consumables, spare parts and tools, as well as a specially equipped room for this purpose.