What Are the Most Common Diesel Generator Repairs?

Diesel generators are essential for business stability, but common issues such as hose leaks, block heater failures, overheating, and fuel spills can cause interruptions. Routine repairs and checks can prevent such instances. Learn about diesel generator repairs, maintenance, and troubleshooting to guarantee maximum performance and lifetime. Get in touch with specialists for support and buying the parts.

When a diesel generator won’t start, the microcosm that it runs stops as well. Unfortunately, rarely do businesses realize they have a problem until the generator refuses to start.

As per the studies of the National Renewable Energy Laboratory, a poorly maintained diesel generator is unlikely to provide power for a duration no longer than a few days and has a reliability of only 80% at 12 hours.

You can avoid such problems by maintaining the generator and knowing the common diesel generator problems.

Keep reading to learn about the causes for needed diesel generator repairs and the ways you can avoid them.

Hose Malfunctions and Fluid Leaks

Leaks are one of the most common problems with a generator. They’re also the easiest problem to spot. If you notice a puddle of fluid accumulating regularly under or around the generator, you have a problem.

Regular maintenance checks spot and prevent basic fuel, oil, and coolant leaks.

Fuel leaks take place around the fuel tank or fuel lines. If you suspect a fuel leak, call a repair technician immediately. Leaky fuel poses an environmental and safety hazard, and it will cause more than just engine damage.

Coolant leaks usually stem from block heaters. High temperatures from the block heater will wear the hoses out faster than other hoses and cause leaks.

Oil leaks are typically not just oil. They often stem from wet stacking or what some people refer to as engine slobber. Fuel, condensed water, acids, carbon particles, and lubrication oil all accumulate and look like an oil leak.

When you take the time to maintain and clean your diesel generator, you will usually find the source of your leaks or prevent them altogether. Inspect your generator weekly, focusing specifically on spotting leaks.

Block Heater Repairs

Engines need block heaters to run properly. The block heater circulates coolant around the engine block, preventing oil from thickening in chilly temperatures.

The block heater maintains the temperature of the cooling system and keeps all parts of the engine warm. Engines typically consist of more than one type of material. For example, pistons consist of aluminum, and cylinder liners consist of iron.

Aluminum expands more quickly than iron. When the iron cylinder liners do not expand as quickly as the pistons, the pistons will scuff the piston skirt and cause damage.

An engine block heater will keep the engine warm so this damage does not occur. You can save yourself significant generator repairs by keeping your engine warm.

Overheating Engines and Low Coolant

Low coolant levels can also cause generator problems. Some generators will sound an alarm when the coolant level dips or rises. Others will just shut down.

If your alarm goes off regularly or your engine shuts down and you have to add coolant frequently, check your generator for leaks. Begin with the block heater hoses.

Inadequate coolant will cause your engine to overheat. This will subsequently damage other engine components and cause long-term damage to the rotor bearings, alternator, exhaust valves, head gasket, and more.

If you ignore your coolant levels and let your engine overheat, you will damage several engine parts and end up needing a new generator altogether.

Fuel Leaks and Gauge Malfunctions

Generators also will not start if they do not have adequate fuel. If you think you’re going through fuel more quickly than you should, check the fuel lines and tank for leaks, and then seek a repair technician immediately.

If your tank runs out of fuel but your gauges say you have plenty, then you most likely have a faulty gauge. Call in a generator repair technician to check the accuracy of your gauges and replace them if necessary.

Dead Battery

Like car batteries, generator batteries usually last several years. You can maximize the life of your battery by maintaining your generator regularly.

A generator not working could be as simple as a dead battery.

If you find yourself with a dead battery regularly, the problem may not just be the battery. You could also have a faulty alternator.

The alternator charges the battery while the generator runs. Thus, if your alternator isn’t doing its job, your battery will die regularly.

Control Malfunction

Generator control panels tell you everything you need to know about your generator’s functions. You should be able to see the oil pressure, battery voltage, coolant temperature, and more.

If your control panel malfunctions, check first to make sure you’ve turned on the automatic controls. If you still have problems, call in a skilled technician to fix the panel.

Avoid Problems, Maintain Your Generator

More than any other reason, poor maintenance leads to diesel generator problems.

To avoid repairing a generator, put your generator on a maintenance schedule. You should have a weekly, monthly, and annual checklist of things to maintain so your generator parts do not wear out.

Plan on either examining the following parts or having a technician inspect these elements regularly:

• Fuel system
• Lube oil system
• Engine monitors
• Cooling system
• Air induction and exhaust
• Safety controls
• Control panel
• Oil and fuel filter changes
• Automatic transfer switch
• Water separator maintenance

When you put together your maintenance plan, include an annual load bank test. This will burn off the unburnt fuel, carbon, and oil that have accumulated in the exhaust system and cylinders. In general, an annual load bank test will eliminate wet stacking.

Furthermore, an annual load bank test will test the cooling and fuel system and then vaporize accumulated moisture that sits in the engine and generator.

If you have air in your system, your generator still may not start. Older types of generators in particular suffer from this problem. If you run a regular maintenance schedule and your generator still won’t start, have a professional technician inspect the generator for this specific problem.

Diesel Generator Repairs Made Simple

Common diesel generator repairs include fixing fluid leaks, heater blocks, control panels, and batteries. Any one of these problems can leave your generator lifeless.

But proper and regular maintenance can prevent most of these problems. If you’re looking for a generator or generator parts, we have what you need.

Our staff takes time to make sure you find exactly what you need for your business by treating every customer with the highest degree of professionalism. We focus on answering your questions and addressing your concerns from the first day you contact us.

Contact us today and let us help you find your next generator.

Common Questions About Diesel Generator Repairs 

1. Which is the most common diesel generator problem?

One of the most common diesel generator problems is fuel depletion. Fuel filters can sometimes get clogged with sludge, or fuel gauges may get stuck, failing to display the correct fuel levels. As a result, the generator uses up all the fuel without your knowledge.    

2.What causes fuel and oil leakage in diesel generators?

Diesel generator fuel leaks can be caused by damaged fuel lines, dried carburetor bowl gaskets, pipe failures, damaged fuel tanks, or faulty shut-off valves.

Possible causes of oil leakage include deteriorated gaskets, incorrectly fitted components, lack of regular maintenance, and extremely high temperatures with inadequate ventilation.

3.How to prevent oil leakage?

If there’s a small leakage due to cracks in the oil tank or pipe, you can clean the damaged area with glue to control leakage.

Use standard rehabilitation glue to clean the worn parts and cure leakage from the diesel engine shaft and sleeve, self-tightening oil seal, valve and valve acne, etc.  

4. Why is diesel generator maintenance important?

Regular diesel generator maintenance helps identify and prevent generator issues. It ensures optimal generator performance and longevity, keeping the backup power source always ready to perform all necessary business functions.

Lack of regular maintenance can lead to decreased efficiency, costly repairs, and even full generator failure.   

5. What are the steps involved in diesel generator maintenance?

The following are some of the key points for proper diesel generator maintenance:

• Perform routine general inspection of the fuel system, exhaust system, engine, and DC electrical system and check for any leakage.
• Maintain the correct oil levels. Replace oil and filters at set intervals.
• Keep an eye on the cooling system and replace coolant filters as required.
• Perform regular diesel generator set exercises to burn up the stored fuel before it diminishes.
  

6.How often should I service my diesel generator?  

Depending on their usage and runtime, diesel generators require different service frequencies. Generally, diesel generators require complete inspection and maintenance by a qualified technician at least once every 6 months.

7.Why is my diesel generator overheating?

Some common causes of overheating in diesel generators include a broken cooling fan, low coolant levels, clogged diesel injectors, a damaged gauge that fails to trigger the cooling system, low oil levels, and damaged exhaust.

8.How to prevent overheating of diesel engines?

The following measures can help prevent overheating of diesel generators:

• Install the generator in a well-ventilated and secure place.
• Ensure the generator is not placed in proximity to other heat-emitting equipment.
• Use quality coolant and fuel. Maintain the right coolant and oil levels.
• Avoid overloading the generator and replace it with a more powerful one if required.

9.How should I proceed if my diesel generator won’t start?

Make sure the crankcase’s oil level is full first by checking it. Next, look for obstructions or trash in the air filter. Clean it or replace it if it’s blocked or unclean.

In the event that your generator has an automated choke system, you may also need to adjust the carburetor float level. Take your generator to a reputable repair facility for diagnostics and repair if none of these other measures succeed.

10.My diesel generator operates normally for a few minutes before shutting down. What could be the reason?

There might be an array of reasons for your diesel generator to quit working after it has been operating. One of them is overheating as a result of inadequate engine oil cooling. Another explanation can be an obstruction in the fuel or air lines, which would impair your generator’s operation.

11.How much does a diesel generator repair cost?

A generator repair may cost more or less, depending on what has to be fixed. A brand-new equipment may cost between $1,000 and $10,000.

However, if your generator just has a few new parts replaced, the cost will be less than $500. It all depends on how much upkeep your particular model needs and which parts need to be fixed or replaced.

12.How long will my diesel generator last?

The longevity of your diesel generator depends on a number of factors, including how often you use it and where you store it. Most generators last between 10 and 15 years under normal working conditions before they require extensive maintenance.

13.How is a transfer switch different from a generator?

Mechanical energy is converted into electrical energy by an electrical generator. A transfer switch is a device that is used to change the direction of the circuit’s incoming electricity.

14.How can I maximize the electricity my diesel generator can produce?

The power output of your generator can be increased in a number of ways.

Run it at a higher RPM because it is the simplest method. Replace your engine with a bigger one as a different choice. You will have greater power for a longer period of time thanks to the increased horsepower and torque you will receive as a result.

As a final resort, you could upgrade or replace specific components of your generator. In order to improve the performance and longevity of the system, this could entail adding an alternator or replacing the brushes or bearings.