Help Centre

Starting Up Diesel Generators for the First Time

Pre-Start Checks

Visual Inspection:

Check for leaks: Inspect for any oil, fuel, or coolant leaks.
Inspect wiring: Ensure all electrical connections are secure and free of damage.
Check for loose parts: Tighten any loose bolts or components.

Fluid Levels:

Engine oil: Check the oil level and top up if necessary. Use the recommended oil type and grade.
Coolant: Check the coolant level and ensure it is filled to the appropriate mark.
Fuel: Ensure the fuel tank is full with the recommended diesel fuel.

Battery:

Charge: Ensure the battery is fully charged.
Connections: Check that the battery terminals are clean and properly connected.

Initial Setup

Prime the Fuel System:

Manual priming pump: If available, use the manual priming pump to remove air from the fuel lines.
Fuel filter: Bleed the fuel filter to ensure there is no air trapped in the system.

Check Air System:

Air filter: Ensure the air filter is clean and properly installed.

Start-Up Procedure

Control Panel:

Set to Manual/Auto: Depending on your setup, ensure the generator control panel is set to the correct mode.
Indicators: Verify that all indicator lights are functioning properly.

Start the Engine:

Preheat (if applicable): Use the preheat function if the generator is equipped with one, especially in cold weather.
Start switch: Turn the key or press the start button to initiate the start sequence.
Observe: Monitor the generator for any unusual noises or vibrations.

Initial Running Checks

Monitor Gauges:

Oil pressure: Ensure the oil pressure gauge reads within the normal range.
Temperature: Monitor the coolant temperature to ensure it stays within the safe operating range.
Voltage and Frequency: Check the voltage and frequency outputs to confirm they are stable and within specifications.

Inspect for Leaks:

After a few minutes of running, inspect the generator again for any signs of leaks or other issues.

Load Testing

No-Load Running:

Run time: Allow the generator to run without load for about 15-20 minutes to ensure it reaches normal operating temperature and stabilize.

Gradual Load Application:

Initial load: Gradually apply load to the generator, starting with 25% of the rated capacity.
Increase load: Incrementally increase the load to 50%, 75%, and then 100%, monitoring the generator's performance at each stage.
Full load test: Once at full load, run the generator for at least 30 minutes to ensure it handles the load properly.

Post-Start Checks

Cool Down:

No-load running: After testing under load, remove the load and let the generator run at no-load for 5-10 minutes to cool down.

Shut Down:

Stop switch: Turn off the generator using the stop switch or button on the control panel.
Fuel supply: Close the fuel supply valve if applicable.

Post-Operation Inspection:

Check fluids: Recheck oil, coolant, and fuel levels.
Battery: Ensure the battery is still fully charged.

Documentation and Maintenance

Record Keeping:

Log book: Maintain a log of all start-up procedures, including date, time, and any issues encountered.
Service schedule: Adhere to the manufacturer's recommended service schedule for oil changes, filter replacements, and other maintenance tasks.

Regular Inspections:

Weekly checks: Perform regular weekly inspections of the generator to ensure it is ready for operation.

Maintenance and Service Schedule

Daily:

Check Fuel Level: Ensure there’s enough diesel fuel.
Inspect for Leaks: Check for any fuel, oil, or coolant leaks.
Visual Inspection: Look for any obvious signs of wear or damage.

Weekly:

Check Oil Level: Top up if necessary.
Check Coolant Level: Ensure the coolant is at the correct level.
Clean Air Filter: Check and clean if necessary.

Monthly:

Run the Generator: Operate the generator for at least 30 minutes under load to ensure it’s running smoothly.
Inspect Battery: Check the battery terminals and clean if necessary.

Every 6 Months:

Change Oil and Oil Filter: Replace with manufacturer-recommended oil and filters.
Inspect and Clean Fuel System: Check fuel lines, filters, and pump.
Check Electrical Connections: Ensure all connections are secure and corrosion-free.

Annually:

Professional Service: Have a professional technician perform a thorough inspection and service, including checking the alternator, voltage regulator, and control panel.

Additional Tips:

Use Quality Fuel and Oil: Always use the recommended types to ensure optimal performance.
Keep Clean: Regularly clean your generator to prevent dirt buildup.
Proper Storage: Store in a clean, dry place when not in use.
Inspect Components: Regularly check mechanical and electrical parts for wear and tear.

Diesel Generator Troubleshooting Guide

Thank you for purchasing a diesel generator from Tracksonhire Ltd T/A Affordable Generators. To help you keep your generator running smoothly, we’ve created this detailed troubleshooting guide. Please review it before contacting our support team at info@affordablegenerators.co.uk.

Common Issues and Detailed Fixes

1. Generator Won't Start

Possible Causes and Fixes:

Battery Issues:

Check: Look at the battery terminals to see if they are clean and the connections are tight.
Fix:
- If the terminals are dirty, clean them with a mixture of baking soda and water. Use a wire brush to scrub the terminals.
- If connections are loose, tighten them with a wrench.
- If the battery is old (typically more than 3 years), replace it with a new one.

Fuel Problems:

Check: Ensure there is enough diesel fuel in the tank.
Fix:
- If the tank is empty, refill it with clean diesel fuel.
- If the generator ran out of diesel, air might have entered the fuel system.

Bleed Air from Fuel System:

Locate the bleed screw on the fuel injection pump.
Place a container under the bleed screw to catch any fuel.
Open the bleed screw with a wrench.
Manually pump the fuel primer or use the manual pump lever until a steady stream of fuel, free of air bubbles, flows out.
Close the bleed screw securely.

Electrical Connections:

Check: Ensure all electrical connections are secure.
Fix:
- Inspect the wires connected to the starter motor and ignition switch.
- Tighten any loose connections with a screwdriver or wrench.
- Replace any damaged wires.

2. Low Power Output

Possible Causes and Fixes:

Overloading:

Check: Compare the total wattage of the devices connected to the generator to its rated capacity.
Fix:
- Disconnect non-essential devices until the total wattage is within the generator’s capacity.

Dirty Air Filters:

Check: Remove the air filter and inspect it for dirt and debris.
Fix:
- If the filter is dirty, clean it by tapping it gently to remove dust or use a vacuum cleaner.
- If the filter is excessively dirty or damaged, replace it with a new one.

3. Overheating

Possible Causes and Fixes:

Low Coolant:

Check: Open the radiator cap (only when the generator is cool) and check the coolant level.
Fix:
- If the coolant level is low, top it up with the recommended type of coolant.

Blocked Radiator:

Check: Look at the radiator for any debris or dirt blocking the fins.
Fix:
- Clean the radiator fins with compressed air or a soft brush.
- Ensure there is nothing obstructing airflow around the generator.

Faulty Cooling System Components:

Water Pump:
- Check: Listen for unusual noises and check for coolant leaks.
- Fix: If faulty, replace the water pump.
Thermostat:
- Check: If the generator is overheating quickly, the thermostat may be stuck closed.
- Fix: Replace the thermostat if it’s faulty.
Fan:
- Check: Ensure the fan is running when the generator is on.
- Fix: If not, inspect the fan motor and connections. Replace if necessary.

4. Black Smoke Emission

Possible Causes and Fixes:

Overloading:

Check: Ensure the load is within the generator’s capacity.
Fix: Reduce the load by unplugging some devices.

Dirty Air Filter:

Check: Inspect the air filter.
Fix: Clean or replace the air filter as described above.

Poor Quality Fuel:

Check: Ensure the fuel is clean and high-quality.
Fix: Drain the fuel tank and refill with clean, high-quality diesel fuel.

Injector Problems:

Check: Inspect fuel injectors for clogging.
Fix:
- Use a fuel injector cleaner according to the manufacturer’s instructions.
- If the problem persists, have the injectors professionally cleaned or replaced.

5. Generator Runs Rough or Stalls

Possible Causes and Fixes:

Contaminated Fuel:

Check: Inspect the fuel for contaminants.
Fix: Drain and replace the fuel with clean diesel.

Air in Fuel System:

Fix: Bleed the fuel system as described above.

Dirty Spark Plugs:

Check: Remove and inspect the spark plugs.
Fix: Clean the spark plugs with a wire brush or replace them if they are worn or damaged.

6. Electrical Issues

Possible Causes and Fixes:

Loose or Damaged Wires:

Check: Inspect all wires for damage or loose connections.
Fix: Tighten loose connections and replace damaged wires.

Faulty Control Panel:

Check: Look for error messages on the control panel.
Fix: Consult the user manual for troubleshooting specific error codes. If unresolved, contact a professional technician.

7. Battery Keeps Dying

Possible Causes and Fixes:

Faulty Charger:

Check: Test the battery charger to ensure it’s working.
Fix: Replace the charger if it’s faulty.

Old Battery:

Check: Inspect the battery for age and ability to hold a charge.
Fix: Replace the battery if it’s old or unable to hold a charge.

If you have any questions or need further assistance, please contact our support team at info@affordablegenerators.co.uk.

Thank you for choosing Tracksonhire Ltd T/A Affordable Generators. We’re here to help you!