Industrial generators are used in many different areas, and each type can have unique problems. Whether a portable generator or a stationary one, each must be maintained properly to keep doing its job. After all, the generator market worldwide revenue has been growing with a CAGR of 10.3% since 2022.
Understanding how a generator works is the first step toward troubleshooting generator problems. Some generator problems are so similar that understanding how a generator works and what causes them can make finding a solution easier.
Expert analysts from Precedence Research have stated that the diesel industry generator market is expected to experience a Compound Annual Growth Rate (CAGR) of over 6.4% through 2030, demonstrating promising expansion in the sector.
The following are some common problems causing generator failure and proven solutions experts weigh in on:
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Not Enough Fuel
Problem: The fuel tanks on the machines with small generators can only hold so much fuel, so if you need to run your generator for an extended period, you may run out of fuel before you finish the job.
Solution: Ensure the fuel valve is open all the way (if there is one) and that there are no obstructions in the line between the tank and the carburetor or filter. Check for leaks in any hoses connected to your generator’s fuel tank or carburetor.
The fuel tank may be empty. Check it before running the generator engine; if it’s empty, refill it while it still runs. It’s best to have plenty of extra gas on hand, especially if you’re using a generator to power tools or other items that use more energy than expected.
Dirty Oil
Problem: It’s another common problem with many generators without an air filter or exhaust system. If the oil gets too dirty, it can cause the engine to overheat and shut down unexpectedly. The engine’s ignition coil may overheat and abruptly shut down if the oil becomes too filthy.
Solution: The best action is to change the oil every 3,000 operating hours or every six months, whichever comes first. This will assist in maintaining the smooth operation of your generator and guard against any significant harm brought on by the lack of lubrication in its internal parts.
As advised by most manufacturers, you should check the oil every time you refuel your generator and change it at least once a year.
Bad Battery
Problem: Research suggests that appliances using generators have grown dramatically, reaching a turnover of USD 396.8 billion last year. If your battery dies while your generator runs, things could become messy unless you have a backup battery charger or extra batteries ready.
Solution: Use a voltmeter or an automobile battery tester to check your battery’s voltage if you think it might be failing. You might have an issue with your unit’s charging system if your generator has been operating continuously for a while.
If so, consider changing the spark plugs before recharging your battery and clearing any accumulated dust around them.
Incorrectly Wired Electrical Connections
Problem: A fire can be started, or an electrical outage can occur by an improperly wired connection, which is unpleasant for everyone involved.
This issue can be brought on by inappropriately connecting wires and attempting to utilize them as intended. This can lead to short circuits that result in sparks and damage to equipment like the internal wiring system of your generator.
Solution: Ensure all cables are placed and connected correctly to prevent this issue and accidentally shorting out anything or creating other problems. Also, ensure the generator has been properly grounded according to local codes and ordinances.
Faulty Tank
Problem: Your fuel tank is full, but your generator fails to start. The fuel line has become clogged with sediment, causing air bubbles below in the tank.
Solution: This problem is easy to fix if you know how to use a siphon pump. To unclog it, siphon out some fuel from your tank using a hose connected to another empty tank or bucket below where you’re standing (make sure no one is around when doing this).
Once you’ve removed enough gas from one side of the clog, flip over your siphon hose so it goes back into the tank from the other side, and repeats until no more air bubbles come out.
Broken Components
Problem: If you don’t maintain your generator correctly, it will start having issues sooner rather than later. This problem is due to inadequate maintenance practices. For instance, the spark plug could become dusty or break, or the fuel pump could stop working.
Solution: Examining your generator’s engine and other moving components, including the vacuum relief valve, main control switch, fuel hose, oil filters, fuel gauges, pump system, and so forth, to help you determine whether this is true. You should repair any broken or malfunctioning parts as soon as you notice them.
Low-Grade Fuel
Problem: This is arguably the most frequent issue with generators, and various factors, such as inappropriate or improper fuel systems or improper storage, can bring it on. This, in turn, leads to engine blocks, clogged fuel lines, fuel leaking, inadequate fuel level, and so forth.
Solution: It is essential to ensure your fuel is clean before you put it into your machine because this can affect your generator’s performance and longevity. Use superior fuels that are clean, well-stored, and free of contaminants.
Erroneous Generator
Problem: An ineffective voltage regulator may result in an early shutdown of your generator. When the generator hits its maximum, the voltage regulator cuts off electricity to prevent overload. You will hear a loud bang as it turns off and on again when this occurs. Your generator might be fine if this occurs just once or twice, but if it happens frequently, you must replace the voltage regulator immediately.
Solution: You should replace your voltage regulator with one that has a higher amperage rating than what came with your generator originally. To determine which size you need, look at the nameplate on your current voltage regulator and see what kind of amperage it has printed there (it will be displayed in amps).
Noisy Generators
Problem: If you’ve ever heard a generator running, you know it can be loud. Some models are significantly louder than others, so choosing the right one for your needs is essential. The noise level of a generator is measured in decibels (dB), and the maximum allowable level is 75 dB. If your generator exceeds this level, it could pose a hazard for people working around it and potentially damage hearing over time.
Solution: Consider generators with mufflers or sound-dampening enclosures to reduce noise levels. These features will help reduce noise by up to 20 dB —enough to make a difference when you’re trying to sleep or relax at home or work.
Discover the Best Generators at Competitive Prices- Swift Equipment Solutions
When buying a generator, it is essential to remember that there is an inherent risk in any mechanical piece of equipment. With any mechanical component, parts will fail, causing a breakdown and, therefore, some scary moments. You can prepare to reduce the number of breakdowns or failures with proper and routine maintenance.
Contact Swift Equipment Solutions today! Our expert team is ready to answer your questions and guide you in finding the ideal solution tailored to your needs. Don’t wait. Get in touch now!
Frequently Asked Questions About Common generator Problems
What is the most typical generator issue?
The most frequent issues with generators are the oil leak and fouled spark plugs. The loose screws are a frequent culprit, but they may be repaired by tightening them. Additionally, it might occur if the oil filter is not tightly sealed or the generator’s spark plugs aren’t replaced.
What is the most common cause for a diesel generator to stop running?
The most common reason a generator stops running is low fuel levels in the tank or dirty oil in the engine.
Why is my generator cutting in and out?
A lousy circuit breaker may cause it, or it could be that the generator is tripping on overloading.
Why is my generator ticking over but won’t start?
If you have fuel in your tank and you hear the engine ticking over, but it doesn’t start, chances are there’s battery failure or a dead battery.
Why isn’t my generator producing any electricity?
Your generator may have ceased producing electricity for many reasons. Low oil levels are one of the most frequent causes of this. The absence of fuel in your fuel tank may also cause your vehicle’s lack of power.
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