Generators PDF Manuals

Repair of gasoline generators

    The main malfunctions of gasoline generators

These generally reliable and durable units, which provide emergency, backup, and sometimes the main power supply of various objects, used during construction and repair work, sometimes fail, and then you have to troubleshoot them. The main ones are the following:

Dirty oil;

Pollution of the air cooling system;

Malfunctions of the ignition system;

Lack of fuel supply;

Starter malfunction.

Experienced craftsmen who maintain gasoline generators often notice that the oil in some of them turns out to be very dirty, almost black. If it was replaced on time, that is, within the time frame stipulated by the maintenance measures, then this means that the unit has quite serious problems with the components and parts that it lubricates. It often happens that when diagnosing such generators, serious problems with the piston group of engines are identified and eliminated, namely, the wear of liners and rings.


If the engine of a gasoline generator starts to overheat, then most likely there are serious problems with its air cooling. Most often they consist in an elementary accumulation of dirt and dust on hot units. To prevent this, the air cooling system must be cleaned regularly.


A much more serious problem arises when problems are detected in the ignition system. Usually they manifest themselves in the fact that there is no spark, and therefore the engine simply does not start. There may be several reasons for this: a malfunction of the ignition coil, the candle itself or the cap. In addition, it often turns out that the wiring is faulty.

If the engine refuses to start, then it is quite possible that the reason for this lies in the fuel system. As a rule, this is due to the use of low-quality fuel. In addition, pollution occurs when generators are idle for long periods of time.

As for the malfunctions of the manual starter, there are usually three of them: a cable break, a broken return spring, and a defect in the ratchet that turns the crankshaft. Of course, you can try to repair a starter that refuses to function normally on your own, but it’s better to entrust this matter to professionals.


Often there are also problems associated not with the engine, but with the electrical part of the gasoline generator. The most common of these is that it simply stops producing current. There can be many reasons for this, ranging from faulty electrical wiring to serious breakdowns of the generating device. If such a problem is observed with an inverter unit, then in the vast majority of cases, they consist in defects in the inverter board.

Repair of diesel generators

Diesel generators today are an excellent alternative for facilities where uninterrupted power supply is required. These are objects of industrial importance, as well as offices, shops. Diesel generators are widely used in everyday human life due to their inexpensive fuel, as well as for conditions of unstable power supply. Especially this point concerns areas where the supply of electricity is uneven, intermittent.


  Diesel generators and power plants are a rather complex structural device. The excellent operation of the units is influenced by several factors, these are the conscientiousness of the manufacturers and the corresponding characteristics indicated in the accompanying documentation, compliance with the rules for operating the units.

  The technical device has accompanying documentation, which clearly indicates its characteristics, as well as recommendations for the use of generators and other equipment. A negligent attitude to these requirements often leads at first to minor malfunctions in the operation of the device, which can later lead to a more complex breakdown, up to the failure of the generator.

  Timely inspection and regular checks of all components and the entire unit as a whole are the key to a stable and long period of operation. Repair of generators with complex faults, as a rule, costs its owner a fairly round sum.


General recommendations

The technical documentation of the units indicates the frequency and rules of inspection.

Check for external integrity of the generator. It should not be cracked, oil should not seep through the body and other openings, and all fixing items in the form of bolts and other screws should be tightly fastened. Check the tension of the belts and clamps.

Pay attention to the operation of the engine at start-up, whether the process slows down, whether the engine stalls immediately after starting. Such malfunctions in most cases are associated with malfunctions in the wiring of the unit.

The presence of fuel in the fuel compartment.

Supply voltage after the start of the generator. The absence of voltage when the device is formally working is usually associated with a breakdown of the voltage regulator.

Faults and solutions

There are several main types of breakdowns. Some of them the owner can eliminate on their own. However, it is recommended that in case of moderate breakdowns, contact special services, since incompetence in this matter, in the future, can lead to a more serious repair of the diesel generator.

  Specialists will first carry out a complete diagnosis of the unit to identify or absence of additional damage.

1. Most of the questions from ordinary users are related to engine overheating.


    Basically, this problem occurs if the rules were initially violated during the installation of the power plant.

    Incorrectly chosen place, including the area of \u200b\u200bthe room.

    Using the generator in climatic conditions unsuitable for its operation.

    The malfunction may be the result of a violation of the calculation of the cooling radiator used in the manufacture of the generator.

    Regular operation of the generator at maximum power with phase distortion.

  2. Excessive fuel consumption can lead to the repair of the power plant. Such a malfunction is expressed in the form of an irregular start and unstable operation at low speeds.

Damage can be caused by the use of low-quality fuel or its shortage.

  Lack of coolant.

  3. Failure (burnout) of the alternator winding. This type of malfunction is not complete without generator repair.

The reason is the connection of devices whose power exceeds the power of the generator itself.

  Phase imbalance during operation of the device.

  The failure of the rewind occurs gradually.

  There are additional malfunctions in the form of too low or high oil pressure, problems with the starter, engine knocking, and so on. In all cases, it is advisable to seek qualified help from specialists. Their experience in a narrow specialty will help to avoid additional costs.