Diesel Generator Problems And Solutions

Diesel Generator Problems And Solutions guide

A diesel generator isn’t only a great investment but it’s also an excellent

asset. However, due to the fact that it is a machine, it is bound to have some problems later on. Some of these problems can be avoided by doing regular maintenance, but some are unavoidable.

Nonetheless, in case your diesel generator starts “acting out”, you should always have a solution at hand. Click here to check out this champion generator on Amazon.

To help you out, below we have compiled some of the most common diesel generator problems and solutions.

This knowledge will be very helpful if your diesel generator does have a problem and it will also prepare you for any issue that may arise.

– Failure to Start

Diesel Generator Problems

Let’s start with the most common problem. Does your diesel generator fail to automatically start?

There are a couple of reasons that could cause such a problem. The most common one is that you have not set the controls to auto.

You can go back to your manual and check out how to set the generator to start when needed.

– Wet Stacking

Wet stacking can be defined as the build-up of unburned fuel in the exhaust system. Also, wet stacking can be caused by long periods of running under a light load.

As a result, forcing the engine to perform under the required temperatures. Signs of wet stacking entail a presence of bluish oil.

If you also notice that the lubricating oil is being over-consumed, that could also signal wet stacking.

To avoid wet stacking, it is advisable that you run your diesel generator with at least ¾ load. This will enable it to reach the required temperature and thus completely burn fuel.

– Burning of Excess Fuel

This is one diesel generator problem that can really create a big dent in your pockets.

Diesel Generator

A generator burning more than the required fuel is a problem that needs to be dealt with as soon as possible.

But how do you know your generator is burning excess fuel? Black sooty smoke is an indication.

This can occur if the injector tips are worn out. A worn-out injector tip is responsible for fuel into the cylinder even when the generator is idle.

To solve this problem, you will need to replace the worn-out injector tips.

– Leaking

leaking generator

Leaking is also another common generator problem. There are three common types of leaks; fuel, coolant and lubricating oil.

Each of these leaks can have very adverse effects on the performance of your diesel generator.

Leaks are bound to happen due to an increase in temperatures, and wet stacking amongst other things.

To avoid leaking, maintenance should be done on the regular.

For instance, all hoses should be replaced after two years.

You can do the replacement earlier than the stipulated period depending on how frequent the generator is used.

It’s why it’s advisable for you to adopt a regular routine maintenance check.

Additionally, gasket failures can also lead to leaking.

At times, leaking may occur and you may not about it because of a malfunctioning fuel gauge.

These gauges may become stuck and as a result, catch you off-guard. It’s best if you manually check the fuel levels.

– Over-heating

over heating

There are some diesel generators that become hot when used for an extended period. However, if you notice an abnormal rise in temperatures, then you need to do something about it.

Overheating is often a result of low coolant levels. You, therefore, need to check that out. If the coolant is in low amounts, then a refill is in order.

Additionally, you should always check the coolant, lubricant and fuel levels before starting your generator.

Most people only check the fuel levels not knowing that the other two are equally important for the proper functioning of the diesel generator. The low coolant levels can mostly be caused by leakages.

– High fuel levels alarms

high level fuel

Do your high fuel level alarms go off frequently? Might worried something to be wrong? Well, you shouldn’t be.

A high fuel level alarm is a standard protocol that is installed in most generators with the aim to notify that the tank is almost full.

The alarm activates when the fuel tank levels exceed 95%. However, in some cases, due to an increase in temperature.

The alarm may activate due to the expansion of the fuel. This can also happen on hot sunny days. You can either switch the alarm off or reset it manually.

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How to Reduce Noise in a Diesel Generator

Diesel generator noise reduction Tips

Diesel generators are more fuel-efficient and require less maintenance than their gasoline counterparts.

Nonetheless, most people shy away from diesel generators due to the worry that they may be too noisy. Thankfully, below are a few effective techniques for making your diesel generator quieter.

Using Anti-Vibration Mounts (AVM)

Reducing the generator’s vibrations goes a long way in decreasing its noise levels. This can be achieved by installing anti-vibration mounts under the generator.

Common types of AVMs include dampers, as well as rubber and spring mounts.

Acoustic Barriers and Insulation

Sound barriers denote solid surfaces that restrict the transmission of noise to external areas by reflecting the waves.

For instance, concrete walls and standard generator canopies go a long way in reducing the noise levels by about 10dB.

An even better noise reduction method involves installing sound-absorbing materials like acoustic wall tiles or panels inside the generator enclosure.

Sound Attenuation Housing

Among the most effective method of reducing noise levels from a large industrial generator entails the use of attenuators.

An attenuator is a large enclosure built of steel. It features perforated sheet metal with high-density rock wall infill known as a splitter, which comes in handy in absorbing sound and reducing wavelength.

Attenuators can be custom built depending on the size of your generator.

Increasing the Distance

The easiest way to reduce noise from a diesel generator is to increase the distance between your house and the equipment.

Moving the generator away from the house allows the wavelengths to disperse at a greater distance, which decreases the acoustic intensity, reducing the noise significantly.

Diesel generators can be quite noisy, especially in quiet neighborhoods. However, this shouldn’t be an excuse for refraining from investing in one.

By the use of anti-vibration mounts, acoustic barriers, sound insulation, and attenuators, you can bring the noise of your generator to bearable levels.

You may also have the generator installed in a far off corner of your home.

How To Repair A Troubleshoot In Your Generator

A generator can be a complicated and complex machine, especially if you don’t know the overall functions of the parts and how to fix it when something goes wrong.

However, it doesn’t have to go downhill from there.

The following is a list of problems that could potentially go wrong in a generator and how to reach each issue:

Fuel problems Oil problems your generator failing to start

When your generator has problems with its fuel, Storing fuel in your generator for lengthy periods of time can lead to a malfunction in your generator.

It’s important to replace the used fuel with fresh fuel to avoid fuel problems in the future.

When your generator has problems with its oil, it’s usually due to a low-level content of the oil.

This can cause long-term damage to the generator and prevents it from running in the first place. Be sure to always check the oil level of your generator.

When your generator fails to start, it’s usually always due to a loss of residue magnetism which is caused when you haven’t used your generator for a long period of time.

How to troubleshoot a diesel generator (Step by step)

Diesel generators could really give peace of mind and give you the capability to use your refrigerator and some other essential appliances; even the power is out.

Because the diesel generator is a significant piece of hardware, it’s vital to maintain and care for it appropriately.

It’s also essential to realize what steps on troubleshooting to take when your diesel generator operates inadequately or would not start.

Step #1

Attempt to turn on the power diesel generator. If the diesel generator would not start, one reason is that the fuel is degraded.

Diesel generators are utilized occasionally; that means they’re unused yet loaded up with gas or fuel.

That fuel would start to deteriorate after some time. At the appropriate time, the fuel quality will end up being a low quality that the unit would not start.

Step #2

Void the fuel tank and put the diesel generator with new fuel. Attempt to control the unit again. If the power diesel generator still would not start, the issue can be a tarnished or stopped up air channel.

Step #3

Take a gander at the spark fitting condition. A very much utilized, chaotic or fouled spark fitting could reduce the operation of your diesel generator.

Various models of the diesel generators were very disposed to flooding.

If your diesel generator isn’t appropriately starting, you should take a gander at the spark plug for the unburned fuel nearness.

Carefully detach the front of the spark plug and disconnect the spark plug.

Take a gander at it for indications of damage and wear, at that point clean and change the attachment. If the spark attachment is damaged or fouled, change it with another one.

Keep several extra spark plugs with the goal that you’ll always have one as a replacement.

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How to Troubleshoot a Generator (Step by Step)

Preventive maintenance is an important method to avoid generator failures.

However, unpredictable problems can happen for a number of reasons to anyone.

To help you solve generator problems, here is a step-by-step guide towards troubleshooting a generator:

1. Make Sure You’re Not out of Fuel

A common reason why generators won’t turn on is a lack of fuel. Sometimes, the fuel level gauges may not be working as intended, for example by getting stuck in position and showing that it still has a lot of fuel, when in fact, it has almost no fuel.

Sometimes low fuel can indicate that there’s a fuel leak. In that case…

2. Dealing With Fuel Leaks

Leaks can occur in systems that do not undergo periodic care or that are exposed to weathering in inappropriate locations, which can cause cracks in the hoses and valves where the fuel passes.

Fuel leaks generally happen when the heater hoses get blocked, leading to high temperatures that often compromises your hoses.

Fuel leakage, in addition to bringing fire hazards, can create new problems and more generator failures.

As such, it is important to periodically check the tank pumping systems and hoses to avoid cracks and signs of aging.

3. Check the Battery

Most generator failures are caused by battery problems. These are commonly caused by the accumulation of sulfates on the battery plates.

Purchasing sealed batteries prevents this from happening, but you should still pay attention to the manufacturer’s guidelines for maintenance and replacement.

4. Check the Circuit Breaker

If the generator fails due to a tripped circuit breaker, you should seek to investigate the reason for tripping.

This will allow you to act at the root of the problem and solve it. Forcing it to restart can be extremely detrimental to the system, which has acted preventively to stop an overload or other risks.

Ready to Do Your Own Troubleshooting?

Now that you know this 4-step process to generator troubleshooting, it’s time to take action and go over each of the points mentioned.

Taking care of fuel renewal and doing preventive maintenance is critical for the generator to be working smoothly whenever it is needed!

Detail About Generator Repair And Service, Gas Generators

Generator faults and Solutions

Having a generator is a suitable arrangement in circumstances where network control isn’t promptly accessible.

A generator can likewise give reinforcement control if there should be an occurrence of blackouts or crises and can be utilized for diminishing power costs during city lattice top hours (top shaving).

Keeping your generator in tip-top condition, hence, is imperative to guarantee that it can give dependable power at whatever point you need it. To do as such, it is fundamental that you have legitimate generator upkeep and adjusting plan for the place.

Generators, anyway huge or little they might be, require steady support to keep them in top running condition.

Regular check-ups and reviews ought to be done at any rate two times every year, and maybe much more if your generator set sees a great deal of utilization.

This guarantees you can recognize any faults or issues at a convenient time, fix them, and avert an increasingly disastrous breakdown (which can be costlier down the line).

A harmed generator won’t productively put out the measure of influence it is appraised with, so keeping yours in top structure augments its yield and, at last, sets aside your cash on fuel and running expenses.

Like some other machine with moving parts, a generator requires legitimate oil.

This is significant. Parts with poor grease make a ton of contact and warmth, causing undue pressure.

This, in the long run, wears your moving parts out a lot snappier.

Abundance warmth can likewise harm different pieces of your generator and cause it to seize up. High oil permits your generator parts to run smoother, more relaxed, and work all the more productively.

The first part that makes electrical power in a generator is called an alternator.

This gadget changes over mechanical movement into electrical vitality. Alternators must be kept spotless and liberated from residue or earth to keep them working appropriately.

Worn out contact focuses ought to be supplanted to guarantee that there is a legitimate association among wires and electrical segments.

Alternator rotors turn at high speeds, so direction and rotor shafts should likewise be very much greased up and examined for any indication of harm.

Need generator fix and administration? It is ideal to have your generator overhauled and kept up by a respectable organization with proficient specialists and specialists to guarantee that your generator conveys top execution when you need it.

Diesel Generator Cranks but Won’t Start

The power is out. The heating or air conditioning is off. The fridge has stopped humming. You go to start your backup generator but something is wrong. It cranks but doesn’t turn on, and you’re starting to worry about that ice cream you bought Tuesday or a long night sleeping in the searing heat or frigid cold.

So what do you do when your diesel generator cranks but won’t start?

How to Prime a Diesel Generator

If your diesel generator cranks but won’t start, it may just need to be primed. Priming a diesel engine means using diesel fuel to clean out any contaminants in the fuel filter.

You’ll want to have your owner’s manual handy before you start this. (As a note, you can use other things to clean a diesel engine besides diesel fuel, such as alcohol, but this may cause fuel mixing later on, which will then cause trouble for your generator.)Using your manual, find the fuel system supply valve and open it.

This will let new diesel fuel get to the engine. Next, open the fuel filter’s bleeder plug to empty it of old diesel fuel. Then, work the priming pump to get rid of any extra fuel or air bubbles. Continue pumping until no more bubbles remain.

You’ll need to repeat this process for all the filters. It may help to mark which filters you’ve already primed. This is also a good time to replace any damaged filters. After this, start the generator in idle mode. If it doesn’t run smoothly, give it a few minutes to run out any other air bubbles.

Diesel Generator Injector Pump

The injector pump could be the issue if your diesel generator cranks but won’t start. This pump supplies fuel to the engine, which makes it pretty important in the process of internal combustion.

Some common problems with diesel injector pumps are dirty fuel, low fuel, bad timing, or foreign objects. • Dirty Fuel – A sputtering engine could be indicative of this problem.

Build-up can accumulate inside the injector pump over time which backs up the system. Using a product such as Standadyne can help.

• Low fuel – Constantly running an engine on low fuel means your generator is pumping a lot of air. Over time, this can ruin it. Keep fuel levels up to maintain a healthy generator.

Bad timing – If the fuel injector pump of your diesel generator has bad O rings or faulty ball seats, it can throw off the timing of fuel transfer to the engine. Unfortunately, a full rebuild or replacement of the fuel injection pump is often required to solve this issue.

Foreign objects – Dust and dirt in the engine can cause clogs in the injector. While there are cleaning products on the market, experts recommend removing the injector and sending it to a professional for cleaning if your injector pump becomes clogged.

Onan Diesel Generator Won’t Start

It seems simple enough, but your generator may just need more fuel. Onan fuel indicators are sometimes off by a hair, and low fuel can lead to trouble even if the indicator says there is fuel available. You may also just need to hold the rocker switch down longer to ensure a proper start.

Checking the coolant levels may also help. Be sure to change the coolant frequently to avoid corrosion and future issues. Another possible source of trouble could be the fuel filter. If your Onan diesel generator won’t start, replacing the fuel filter could be the fix.

Yanmar Diesel Generator Won’t Start

You want to start with any obvious causes like low fuel or blocked ventilation areas. Make sure there is nothing blocking the inlet ports like a rag or debris.

Ensure the stop cable is in working order and that it hasn’t become locked in an off position. If it has, it can make the generator difficult to start. If these aren’t the problem, you may need to check the fuel injector.

You can check this by removing it and starting up the generator. Be sure to stay clear of any potential spray. If your injector pump appears to be working, add lubricant to the injector bore to help seal the O rings, and then place it back in your generator. Carbon deposits on the injector face may be the culprit here.

You’ll find these around the center pin, and they can be carefully scraped off using a knife or other sharp tool. If all else fails, a starting fluid may help you kickstart your generator into working gear. Use starting fluids sparingly as they can wear down your machine.

How to Remove Air from Diesel Generator

Removing the air from a diesel generator is referred to as bleeding the fuel line. As any air being pumped into the engine is going to cause problems, it’s important to know how to do this in case your generator engine fails.

Before accessing the fuel lines, check fuel filters for proper installation and any clogs. If necessary, change these filters before proceeding. Next, consult your owner’s manual to see how to access the fuel lines of your diesel generator. Remove the valve cover using an appropriate tool.

Then, locate the injector that will give you fuel. You can consult the owner’s manual for its location, but it should be the forward-most injector in most cases.

Carefully bleed any fuel from your generator. Always use appropriate tools and safety equipment, and make sure that you follow appropriate precautions.

Bleed the engine until the fuel that comes out no longer contains air bubbles. When the fuel comes out clean, close up the injector and return everything to its original position. If excess air in your fuel line was the reason that your generator would not properly run, this should solve that issue.

In closing, there are many possible reasons your generator cranks but won’t start. It may take some trial and error to figure out the problem, but there are ways to potentially save your generator and avoid the high costs of a replacement.

Always be sure that you follow the recommendations of the manufacturer and your owner’s manual, as well as any safety standards.


The above are six diesel generator problems and solutions on how to tackle them. A diesel generator as mentioned earlier is useful machinery.

In case of an outage, it is a reliable source of power. A malfunctioning generator can interfere with your daily operations it’s why you should familiarize yourself with these problems and how to solve them. Champion 3400 is a great generator that you can check here.

The best way to avoid such problems from arising in the future is by doing frequent routine checks and maintenance. The two will always keep you a step ahead.

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