Most diesel generator piston head covers undergo erosion at the upper end of the piston and in the first and second piston ring grooves. The main forms of damage include: top surface melt holes, perforations, pits, keyways at the upper end, collapse, or complete erosion at the upper end.

The main causes of the malfunction and piston burning are as follows:

1. Severe carbon accumulation on the upper end of the piston. The carbon buildup on the piston crown causes a portion of the upper end of the piston to overheat, resulting in hot weather. When some high-temperature weather exceeds the melting point of the raw materials, the upper end of the piston will melt and form a molten cavity.

2. The piston ring adhesive may bond or crack. Bonding or cracking of piston rings can prevent close contact between the piston rings and the cylinder wall, prevent the timely discharge of heat energy from the piston crown, and lead to the escape of air in hot weather, resulting in the burning of the piston crown and ring groove.

3. Uneven oil supply. The fuel supply and supply time of each cylinder in the internal combustion engine are inconsistent, and the combustion process of some cylinders deteriorates, forming carbon deposits and severe afterburning. The thermal energy of diesel combustion cannot work, and the piston top temperature of some cylinders is too high, resulting in thermal fatigue and melting of raw materials.

4. The nozzle cannot function properly. When there is too much oil accumulation at the upper end of the piston, a part of the temperature is too high, and the thermal stress increases. When there is too much oil accumulation at the upper end of the piston, a part of the temperature is too high, the thermal stress increases, and it burns out.

5. The nozzle cannot function properly. When diesel generators are in operation, the piston crown should withstand periodic mechanical impacts of combustion and explosion, with an instantaneous impact force of over 10.0 megapascals.

6. The oil cooling nozzle is blocked. Some diesel generators are equipped with oil cooling nozzles on the body, which can spray oil into the piston chamber to help cool and dissipate heat. If the oil cooling nozzle is blocked, the piston will become hot, which can easily cause the piston to burn out.

7. Diesel generators operate at overload and overspeed for a long time, or have poor heat dissipation. Long term exposure to excessive thermal and mechanical stress can easily lead to fatigue and erosion.

8. The piston is not qualified. Under high temperature and pressure, if the piston has defects such as porosity, shaking, microcracks, and slag inclusion, some porosity, shaking, and microcracks will become sources of fatigue, leading to fatigue damage; The piston slag melts first, causing the upper end of the piston to melt.

9. Frequently stepping on the accelerator pedal causes the diesel generator to operate at high speeds and loads, resulting in excessive temperature and extreme heat erosion of the upper end of the piston.

When air leakage and other factors in the onboard air compressor of a diesel generator cause excessive exhaust, a large amount of oil enters the intake pipe of the diesel generator through the exhaust pipe of the crankcase respirator, and enters the combustion chamber to participate in combustion. The upper part of the piston burns.

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