Prime Culprits of Soared Fuel Consumption for Your Diesel Generator Set

Clogged or Worn Fuel Injectors

Injectors are critical for breaking fuel into fine droplets (atomization) to mix with air. Over time, impurities in fuel (e.g., dirt, carbon deposits) clog injector nozzles, or wear causes nozzle deformation. This leads to:

Poor fuel atomization (large fuel droplets that can’t fully mix with air).

Uneven combustion (unburned fuel is discharged as exhaust, wasting fuel).

Example: A worn injector may increase fuel consumption by 15–25% for a 100kW generator.

Poor-Quality Fuel

Using diesel that fails to meet standards (e.g., high sulfur content, water contamination, or improper viscosity) disrupts combustion:

Water in fuel causes misfiring (unburned fuel is wasted) and corrodes fuel system components.

Low-quality diesel with heavy hydrocarbons burns slowly, leaving uncombusted residues and increasing fuel use.

Clogged Air Filter

The air filter prevents dust, sand, and debris from entering the engine. Over time, it accumulates dirt, restricting airflow:

Reduced air intake → too much fuel relative to air.

Unburned fuel is exhausted as black smoke, directly increasing fuel consumption.

Warning sign: A heavily clogged filter can raise fuel use by 10–18% and cause engine power loss.

Soared fuel consumption is often a sign of multiple aging-related issues. HUAQUAN Power suggests conducting a full maintenance for its diesel generator set every 1000 hours of operation. This will not only improve the fuel efficiency but also extend the service life of the unit.