Generator Faults: Common Issues 

Generator faults often lead to unexpected downtime and equipment failures, making it essential to understand what causes them and how to troubleshoot effectively. This guide explores common problems such as startup failures, electrical faults, and engine issues for both petrol and diesel generators, as well as standby and portable models, with practical solutions to keep your equipment running efficiently. Whether you’re facing fuel issues or overheating, a solid understanding of generator faults can save you time and money in the long run.

Most Common Generator Faults and Causes

Below, we explore prevalent issues for petrol and diesel generators, including specific troubleshooting for standby and portable units.

1. Generator Won’t Start

Generators that refuse to start are a common and stressful issue for many users, whether it’s a backup unit for emergencies or equipment used daily. Several factors could prevent your generator from starting, including:

• Fuel System Problems: Degraded fuel quality can lead to startup issues. In both petrol and diesel generators, ensure the tank has fresh fuel. For petrol models, remember that ethanol content in some petrol types can reduce fuel stability over time. In both fuel types, check for blockages or leaks in the fuel lines, which may hinder fuel flow.

• Portable Generators: Portable petrol units are particularly susceptible to fuel degradation if stored for long periods. Make it a habit to empty the fuel tank if you don’t plan to use the generator for an extended time.
• Standby Generators: Standby diesel generators often have more robust fuel systems but may suffer from fuel contamination over time. Inspect fuel filters regularly and replace as needed to ensure smooth operation.
• Battery Issues: Standby generators, typically diesel-powered, rely heavily on a charged battery for an automatic start. Check for corroded terminals and ensure tight connections. In older batteries, replacement may be necessary, especially for diesel units, which require higher cranking power to start.

Engine Troubleshooting:

• Petrol Engines: Check the spark plug for fouling or wear. Avoid using a wire brush, as this can damage sensitive components; instead, replace if needed.
• Diesel Engines: Diesel models may experience issues with glow plugs or injectors, which can cause startup problems if worn or clogged. Regular maintenance of these parts will help reduce failures.
• Resetting Controls: For both petrol and diesel units, check the control panel to ensure all emergency stop buttons are disengaged and settings are properly configured.

2. Voltage Fluctuations and Power Output Issues

Stable voltage output is critical to preventing damage to connected equipment. Voltage instability can arise from several factors and may impact portable and standby generators differently:

• Faulty Voltage Regulators: Common to both types, a failing voltage regulator disrupts stable output. Regular inspections can prevent fluctuations and protect sensitive electronics.
• Load Management: Overloading destabilises voltage output, although the tolerance levels may vary:
  • Faulty Voltage Regulators: Common to both types, a failing voltage regulator disrupts stable output. Regular inspections can prevent fluctuations and protect sensitive electronics.
  • Load Management: Overloading destabilised voltage output, although the tolerance levels may vary:

• Wiring Issues and Environmental Factors: Damaged or improperly connected wiring affects both generator types, causing voltage instability. Inspect for corrosion and loose connections. Extreme temperatures can also impact both types; place the generator in a well-ventilated and protected area to minimise environmental impact.

3. Battery Failures in Generators

Battery failure is a common issue in both portable and standby units, especially in diesel standby models that rely on a charged battery for startup.

• Age and Wear: As batteries age, their charge-holding capacity diminishes. Regular replacement is particularly critical for diesel standby units, which often require a fully charged battery for automatic starting.
• Corrosion Prevention: Keep terminals clean with a mixture of baking soda and water to maintain good connections.

Infrequent Charging: Diesel standby units that aren’t regularly run may suffer from undercharged batteries. Schedule periodic starts for these models to maintain battery health and ensure operational readiness.

4. Overheating Issues in Generators

Overheating can occur in both petrol and diesel models, though there are some notable differences based on usage and type.

• Low Coolant Levels: Diesel generators, particularly larger standby units, often require a more robust cooling system, and low coolant levels can cause overheating. Check coolant levels regularly and refill with the manufacturer’s recommended fluid to maintain proper cooling.
• Clogged Radiators and Worn Components: Dirt and debris can obstruct radiators, impeding cooling. Both petrol and diesel units benefit from regular cleaning to ensure efficiency. Components like water pumps, thermostats, and hoses wear out over time, particularly in standby diesel models that may run for longer periods.
• Oil Levels and Environmental Protection: Low oil levels often trigger overheating in both petrol and diesel generators. Regularly check oil levels and look out for leaks. Ensure proper ventilation and shielding from weather extremes, especially for larger standby units that may need to run continuously during outages.

Maintaining your generator’s efficiency is crucial for avoiding unexpected downtime and costly repairs. By applying the troubleshooting and maintenance tips shared, you can ensure your generator meets your power needs.

If you encounter persistent issues or need professional support, our expert team is ready to assist. We offer services such as diesel generator servicing, generator repairs, and installation tailored to keep your generator running smoothly.

Our expertise also includes UPS installation and servicing, ensuring your backup power systems are reliable. For those considering an upgrade, we provide comprehensive site surveys and generator sizing guides to help you make informed decisions.

Don’t let generator faults disrupt your operations. Contact us today to schedule your service and ensure uninterrupted power supply.