Importance Of A Generator Maintenance Program

The modern day electrical grid delivers reliable electricity to countless homes and businesses throughout this great nation. Unfortunately, electrical grid failures are becoming common with weather events, accidents and sometimes the powers that be, force a black out to avoid bigger problems.

While natural disasters are impossible to predict, major equipment failures present opportunities for mitigation. Prepare for them with a generator maintenance program by Generator Source.
 
There are many ideas that come to mind when dealing with standby power and outages. Start by ensuring the diesel generator’s batteries are fully charged and tested regularly under a load. A faulty battery ensures the generator will not run when a power outage occurs. 

Standby Used Industrial Generators Save You Money

When residential power is lost, for the most part, it’s just an inconvenience. Sure, it could mean life or death for the elderly or unhealthy people during a heat wave or deep freeze. But when power goes out for large buildings like a hospital, it can be disastrous and costly.

From hospitals to data centers, the repercussions of a power outage can be extremely costly and dangerous. A study by the Department of Energy stated that financial losses from a power outage at data centers can range from $20,000 to $2 million per event.

Other facilities that are pivotal in ensuring a standby power system runs smoothly includes airports, water/sewage treatment plants, government offices, police and fire stations. Every one of these facilities have an industrial generator installed in the event of a power outage.
 
According to Diesel Technology Forum, diesel-powered generators provide the most reliable form of emergency backup power for businesses when the grid goes down.

Backup generators typically can run for 30,000 hours or more but the system needs to be exercised and maintained on a regular basis. This ensures the machine operates correctly for the long term. Whenever a standby generator fails to start or perform as desired, it’s typically due to a faulty maintenance program.
 
The following is a list of maintenance procedures that need to be performed on a regular basis.

> General inspection
> Lubrication service
> Cooling system service
> Fuel system service
> Servicing and testing starting batteries
> Regular engine exercise 

Generator General Inspection

Operators should be alerted to mechanical problems that might occur during operation. The following are several systems to service and maintain on a regular basis. 

• Exhaust system: You should inspect the entire system which includes the manifold, muffler, and exhaust pipe. Inspect for leaks at connections, gaskets, and joints. Ensure the exhaust pipes are not overheating surrounding areas. Inspect for a surplus of smoke when starting the industrial generator.
•  Fuel system: Inspect the entire system which includes the supply lines, return lines, filters, and fittings. Ensure the lines are not rubbing against elements which could fail later in time.
•  Engine: Inspect fluid levels, coolant temperatures, and oil pressure frequently. Listen to any changes to the engine sound or performance which may indicate service or repair is needed.

Lubrication Service

An industrial generator technician will check the engine oil level when the generator is turned off. Performing this check when the engine is off allows for a more accurate reading. The generator technician will follow guidelines provided by the engine manufacturer’s recommendations. Our industrial generator technicians will check the oil and filters, later disposing unusable materials in an environmentally conscious way. 

Cooling System Service

Generator Source’s experienced technicians will also check coolant levels during shutdown periods. Our techs will remove the radiator cap after the engine has cooled down.Large diesel generator engines require a balanced coolant mixture of antifreeze, additives, and water. Our used generator technicians will use coolant solution’s the engine manufacturer recommends.

Our generator technicians will also inspect the exterior of the radiator, removing any dirt or foreign material that may cause issues.

Fuel System Service

Diesel fuel can become contaminated and deteriorate over time which is a big reason to regularly exercise a generator. It's a good idea to use up any stored fuel before it degrades.Technicians will also drain the fuel filters because water vapor accumulates and condenses in the a generator’s fuel tank.
 
If the industrial generator is located in a warm climate, bacterial growth in the fuel can be a problem. Regular generator testing and fuel polishing would be required in such climates if the fuel is not used up every three to six months.
 
Generator preventive maintenance should encompass on-going general inspections which include checking starting system, fuel system, coolant level, and oil level.

Starting Batteries

Undercharged starting batteries is a common reason for any standby generator power system to fail. Even fully charged batteries are subject to deterioration over time. Batteries should be replaced every 24-36 months.

Used Generator Set Exercise

Emergency standby generators must be able to operate from a cold start to being fully operational in seconds. This fact requires regular engine exercises to ensure the machine will operate properly when it’s needed. Regular exercising uses up old fuel that is deteriorating, prevents oxidation of electrical components, and helps lubricate all engine parts.

Our technicians recommend exercising a unit at least once a month for a 30-minute period.
Contact the team at Generator Source for all your used industrial generator needs today!

Story Summary

How often should I perform maintenance on my diesel generator?
Maintenance frequency depends on usage, but generally:

• Perform visual inspections weekly
• Check fluid levels monthly
• Change oil and filters annually or every 200-300 hours of use
• Conduct a full service annually

What are the key components to check during routine maintenance?
The main areas to inspect include:

• Engine oil and coolant levels
• Fuel system and filters
• Battery condition and connections
• Air intake and filters
• Belts and hoses
• Exhaust system

How often should I exercise my standby generator?
Generators should be exercised at least monthly for 30 minutes under load. This helps prevent fuel degradation and keeps components lubricated.

When should generator batteries be replaced?
Most generator starting batteries last 2-3 years. Replace them proactively every 24-36 months to prevent failure.

What type of fuel is best for long-term storage in diesel generators?
Use ultra-low sulfur diesel fuel and add a fuel stabilizer if it will be stored for more than 6 months. Regularly test fuel quality and consider fuel polishing for long-term storage.

How can I tell if my generator needs servicing?
Signs that service is needed include:

• Difficulty starting or frequent stalling
• Excessive exhaust smoke
• Unusual noises or vibrations
• Decreased power output
• Warning lights on control panel

Should I hire a professional for generator maintenance?
Basic checks can be done yourself, but it's recommended to have annual services performed by a qualified technician. This service call will ensure proper maintenance and catch any issues. Our team of field service technicians are availalbe in Colorado, Southern Wyoming, Florida, Southern Georgia, Southern Alabama and the great Austin, TX region. Learn more here.