Diesel Generator Fuel Injectors – Problems? – Technical Support

Fuel injectors in a diesel generator rely on two essential elements: clean diesel fuel and oxygen, supplied in the right proportion without interruption to the engine. Fuel injectors have a crucial role in this process as they receive diesel fuel from the injection pump and then convert it into a finely dispersed mist, allowing the engine to operate smoothly and efficiently. However, various issues can arise that may impact the optimal performance of the injectors. Some of these issues include:

Generator Fuel Injector Leaks

If injectors are leaking, you may notice:

• a strong smell of diesel in the vicinity of the generator.
• the generator is difficult to start.
• fuel consumption suddenly increases.
• fire!

Solution- Any of the above can occur with Diesel generator fuel injectors, especially when an injector cracks or O-ring seals become hard and brittle with age.

Multiple issues occur especially with old Injectors

• Reduced Fuel Atomisation: Over time, the injector nozzles can become worn or clogged with carbon deposits. This can lead to improper fuel atomisation, resulting in less efficient combustion and reduced engine performance.

• Fuel Leakage: Aging injectors may develop leaks, causing fuel to escape into the engine bay or surrounding components. Fuel leakage can lead to fuel system contamination, decreased fuel efficiency, and potential safety hazards.

• Inconsistent Fuel Spray Pattern: Wear and tear can cause the injector's spray pattern to become uneven or erratic. This can disrupt the precise fuel distribution required for optimal combustion, leading to rough engine operation, decreased power output, and increased emissions.

• Increased Fuel Consumption: Aging injectors may deliver an improper amount of fuel or exhibit poor spray pattern control. This can result in increased fuel consumption, reducing the generator's overall fuel efficiency and increasing operating costs.

• Hard Starting or Misfiring: As injectors age, they may struggle to provide the necessary fuel volume or pressure for proper starting or combustion. This can lead to difficult starting, extended cranking times, or misfires, impacting the generator's reliability and performance.

• Excessive Emissions: Aging injectors can contribute to higher levels of exhaust emissions, including harmful pollutants such as nitrogen oxides (NOx) and particulate matter. Increased emissions not only harm the environment but may also prevent compliance with regulatory standards.

Generator hunting or struggling when running- What’s the problem?

The fuel atomising spray is disrupted by deposits gradually accumulating. Found within the injector tips.

Resulting in a build-up of burnt fuel or fuel additive residue in the injectors. Each time the generator shuts down the deposits remain. Including rust particles that have travelled through the system to the injectors. These obstructions will either disrupt the spray or, if left unchecked, block the injector completely, preventing fuel from getting into the engine.

Check for:

• Engine misfiring on start up (audible issue you’ll hear this).
• Difficulty in starting the generator.
• White smoke.
• Dirty fuel or diluted fuel (cheap diesel from a non registered supplier).

Solution –Take out the injectors and thoroughly clean them before replacing them in the engine.

Generator Fuel Injector Failure

Elements within the injector will wear or generally fail over time, leading to various problems. These may include a valve that won’t close and therefore leaks fuel or a valve that won’t open and therefore won’t supply fuel to the engine.

Solution –Take out the injectors and thoroughly clean them before replacing them in the engine.

Finally, if that doesn’t improve the performance of the engine you’ll require brand NEW Injectors.

Regular servicing regime-If the above issues are not addressed through regular preventative maintenance, then the generator’s performance and efficiency will be reduced. Power Continuity Systems offer a complete service and maintenance package with each generator installation that will ensure that the fuel injectors are kept in good working order.

If you’re looking for New Diesel Generator Fuel Injectors, call us on 0845 055 8455, we’re here to help!