Generac Generators Exposed: A Deep Dive into Common Generator Problems

Ah, the mighty Generac generator – a trusty and reliable companion during those pesky power outages. But let’s face it, even the most loyal friends can have quirks. In this article, we’ll dive deep into the common problems with Generac generators, and, spoiler alert: we’ve got the solutions too!

From battery failures to air filter problems, we’re leaving no stone unturned in our quest to expose the nitty-gritty of these power-producing pals. So, whether you’re a seasoned Generac owner or just starting to flirt with the idea of acquiring one, this article is your one-stop shop for understanding and troubleshooting the most common generator problems.

Put on your detective hat, and let’s unravel the mysteries of Generac generators together. By the end, you’ll be armed with the knowledge and confidence to tackle any generator issue that dares to darken your doorstep.

Most Common Generac Generator Problems & Solutions

Generator Battery Failure

One of the most common reasons for generator failure is a dead battery. Sulfation buildup from the battery plates can decrease the battery’s lifespan, causing it to die sooner than expected.

To keep your generator running smoothly, performing routine maintenance on the generator’s battery is essential, such as checking and cleaning the terminals.

Failure to Start: Fuel Tank and Choke Issues

A Generac generator may refuse to start for several reasons, including an empty fuel tank or a clogged choke.

Before starting the generator, check your fuel levels and ensure you fill the tank with the correct fuel type, such as diesel or natural gas. Additionally, inspect the choke for any debris or buildup that could hinder its operation.

Stalling During Operation: Spark Plug and Air Filter Troubles

When a generator starts but stalls during operation, common culprits include worn spark plugs or clogged air filters.

Regular maintenance, including inspecting and replacing spark plugs and cleaning or replacing air filters, can prevent these issues and keep your generator running smoothly.

Clogged Fuel Lines and Carburetor Concerns

Clogged fuel lines and carburetor issues can cause generator failure, as they restrict the fuel flow into the engine.

Invest in routine fuel treatment and maintenance to avoid these problems to ensure your generator’s fuel system stays clean and functional.

Low Coolant and Block Heater Hose Failure

Low coolant levels and block heater hose failures can lead to high temperatures throughout the engine, causing costly damages and downtime.

As the water in the coolant evaporates over time, it’s crucial to check and top off coolant levels regularly. Additionally, inspect hoses and drive belts for signs of wear or leaks and replace them as needed.

Leaks: Oil, Fuel, and Coolant

Oil, fuel, and coolant leaks can cause generator problems and damage the engine. Regular maintenance on a unit, including checking for leaks and sealing any gaps, is essential for preventing leaks and maintaining a working generator.

Wet Stacking and Exhaust System Complications

Wet stacking, a buildup of unburned fuel and condensed water in the exhaust system, can cause a generator to produce less power and eventually fail.

Installing a recirculating breather or using fuel additives can help prevent future wet stacking issues. Additionally, inspect the exhaust system for signs of buildup or damage, and clean or repair it as necessary.

Fuel Depletion and High Fuel Level Alarm

Running out of fuel or having excessively high fuel levels can lead to generator issues. Regularly check fuel levels, and avoid overfilling the tank.

If your generator doesn’t start even when the fuel tank is full, consult a professional to troubleshoot and address the underlying issue.

Proper generator maintenance, including regular inspections and addressing common problems, is crucial for ensuring your generator functions efficiently.

By staying proactive and performing routine checkups, you can extend the life of your generator and avoid costly repairs or replacements.

Generac Generator Maintenance: The Key to Reliability

Avoiding Sensor, Connection, and Circuit Board Failures

Ensuring the reliability of your Generac generator means paying attention to sensors, connections, and circuit boards.

Regularly inspecting and testing these components can help you catch any issues before they lead to more severe problems, such as a generator failing to start or producing less power.

By addressing these issues promptly, you can maintain your generator’s reliability and prolong its lifespan.

Preventing Fuel Failures and Clogs

Fuel failures and clogs can be the bane of any diesel or natural gas generator owner. To keep your generator running smoothly, it’s essential to check your generator’s fuel levels when filling the tank and use the appropriate fuel type.

Additionally, perform routine fuel systems maintenance, such as cleaning or replacing filters and using fuel additives to prevent clogs or other issues.

This proactive approach will ensure your generator produces enough power to keep running when needed.

Removing Single Point Failures (N+1)

In commercial generators, the N+1 principle is essential for maintaining reliability. This approach involves having backup systems to ensure that if a single component fails, the generator won’t stop working.

By eliminating single points of failure, you can ensure your generator remains operational and avoid costly downtime.

Regularly inspect and maintain all aspects of your generator to guarantee its performance, even when faced with unexpected issues.

The Total Solution Approach to Reliability

Taking a total solution approach to reliability means addressing every aspect of your generator, from fuel systems and sensors to exhaust systems and filters.

Commit to regular maintenance at least once every month, including checking for fluid leaks, monitoring fuel levels, and inspecting all components for wear and tear.

By being proactive and thorough, you can reduce the risk of your generator failing when needed.

Expert Tips: Troubleshooting Your Generac Generator

Quick Fixes for a Generac Generator That Won’t Start

If your diesel or natural gas Generac generator doesn’t start, don’t panic! Many issues can be resolved with some simple troubleshooting. Here are six expert tips to help you get your generator up and running again:

Checking Oil and Fuel Levels

Low oil or fuel levels can prevent your generator from starting. Ensure you’re filling the tank with the appropriate fuel type and that there’s enough oil in the engine. Regularly checking and topping off fluids can help prevent future issues.

Assessing Choke and Fuel Valve Functionality

A malfunctioning choke or fuel valve can also cause your generator to fail. Inspect these components for any debris or damage and ensure they function correctly. If necessary, clean or replace them to restore proper operation.

Cleaning the Air Filter and Carburetor

Clogged air filters and carburetors can hinder your generator’s performance. Make sure to clean or replace the air filter and remove any debris or buildup from the carburetor.

Maintaining these components will help your generator run efficiently.

Repairing or Replacing the Spark Plug

A worn or damaged spark plug can prevent your generator from starting. Inspect the spark plug for signs of wear or damage and repair or replace it if necessary.

Regularly checking and replacing spark plugs can ensure your generator starts when needed.

Resolving Dead Battery Issues

A dead battery is a common reason a generator won’t start. Check your generator’s battery and replace it if needed. Regular battery maintenance, such as cleaning terminals and checking for sulfation buildup, can prolong its life and keep your generator running smoothly.

Unplugging the Generator Before Starting

Finally, always remember to unplug your generator before attempting to start it. Plugging it in before starting can cause it to back feed power, potentially damaging the generator or any connected devices.

Conclusion: The Importance of Maintenance in Avoiding Common Generator Issues

In conclusion, maintaining your diesel or natural gas generator is crucial for avoiding common problems and ensuring reliable power generation.

Whether you have a newer or older generator, regular upkeep can help prevent issues like oil leaks, pump system failures, fuel leaks, and more.

One of the most essential aspects of generator maintenance is addressing common generator problems and solutions before they escalate.

You can save time and money on costly repairs or replacements by troubleshooting generator problems early on. Keeping your generator in peak condition means staying on top of issues like fuel levels, engine temperatures, and fluid leaks.

Regarding diesel generators, proper care also involves monitoring the engine’s fluids, gases, and filters.

This includes checking and changing filters every three to four years, ensuring that the engine has the necessary fluids, and installing a recirculating breather to minimize buildup in the exhaust system. Addressing these elements can reduce the risk of wet stacking, leaks, and other complications.

Natural thermal expansion occurs when the engine heats up and can also cause wear and tear on your generator.

Regularly checking and replacing components, such as hoses and belts, can help you avoid issues related to high temperature.


Which Generac generators are being recalled?

Recalls for Generac generators can vary over time. To get the most accurate and up-to-date information, visit the Generac website or the Consumer Product Safety Commission website, where they list recall notices and affected models.

Are Generac generators made in China?

Generac generators are primarily manufactured in the United States, with some components sourced globally. Generac prides itself on its American-made products and has manufacturing facilities in Wisconsin, South Carolina, and other states.

What Generac generator is on the recall list?

To determine if a specific Generac generator is on the recall list, check the Generac or Consumer Product Safety Commission websites. Recall information is regularly updated, so staying informed is essential to ensure your generator’s safety and reliability.

How much does it cost to replace a Generac generator?

The cost of replacing a Generac generator depends on the model, size, and installation requirements. Prices range from a few thousand dollars for smaller residential generators to tens of thousands for large commercial units. Therefore, comparing costs, features, and customer reviews is a good idea before deciding.

John S.

Hello guys! I'm a 37-years-old author, traveler, writer, blogger, and a camper. I enjoy life as much as I can and love to visit beautiful places in my RV. That's why while traveling I have decided to dedicate some time to share my experiences with everyone that might be interested in traveling, camping, and RVs.

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