Unexpected power failures can halt production, disrupt workflows, and cause downtime, but well-maintained generators guard against this. When a storm hits and power gets cut off, your generator should kick in effectively. This would only be possible through regular generator maintenance, which prevents breakdowns and keeps operations running smoothly.
For safe operational readiness and a long service life, having a solid maintenance plan is mandatory. This allows your generator to remain in peak condition. Read on to find out about the essentials of generator maintenance, including important steps and common issues (as well as how to fix them).
How often should generator maintenance be conducted?
Even if the generator runs only occasionally or not at all, maintenance is necessary at regular intervals. Otherwise, the machine breaks down. Condensates form, contaminating the oil and making it unusable. In addition, regulators can stick and hoses become porous, which can result in larger, more costly repairs.
How often maintenance needs to be done depends on the model. Regular maintenance is usually associated with warranty claims. Therefore, specifications on the maintenance schedule from the manufacturer can be found in the operating instructions. The maintenance of generators is usually carried out by specialized service teams or employees trained for this purpose in the company.
In general, though, generators in most industries would need preventive maintenance at least once a year, or after around 400 hours of use.
Important tasks for generator maintenance
Wherever electricity is involved, care must be taken. Before starting maintenance work, a power generator must first be switched off. In addition, the spark plug connector should always be disconnected. In addition, original parts should always be used, which are suitable for the respective generator, otherwise it can lead to significant damage.
Maintenance work can and should be done internally at regular intervals, especially if the generator is frequently in use. This work is primarily about extending the service life.
Here’s a breakdown of the specifics:
Run the generator
The engine oil will degrade if it sits idle for a long time. Therefore, it is important to run the generator for around 5 to 10 minutes during maintenance to prevent corrosion. This will also ensure that the generator remains in good working condition. While the generator is running, listen for unusual sounds like knocking or sputtering, which could be signs of internal problems.
Check for signs of damage
The most important task during maintenance is to check for damage that could involve repair. First, check the housing for any cracks or dents. Then inspect the fuel system for any leaks or blockages. Tighten any loose fittings and replace damaged hoses right away.
You’ll also need to pay special attention to the exhaust system and engine. Check for soot buildup or corrosion around the exhaust pipes, which might be a sign of blockages or leaks. For the engine, look around the seals and gaskets for oil leaks. You can take a clean rag and wipe it over areas of the generator to detect any leaks.
Inspect and test the battery
Do a visual inspection on the battery and look out for signs of corrosion on the terminals–this can show up as a white, powdery substance, which should be cleaned off. All connections should also be tight. You can then test the battery with a multimeter to assess the voltage. If the voltage is too low, recharge the battery or consider replacing it if it fails to hold a charge.
Remove dirt and dust
Keeping your generator clean is just as important as running it regularly. Once the generator has been turned off and is completely cool, you can use a compressed air cleaner to remove dust and debris from the cooling vents and other hard-to-reach areas, especially the air intake and exhaust systems. Aside from reducing efficiency, too much dust inside can also lead to overheating since the dirt is blocking the airflow.
Change engine oil
On the one hand, the engine oil serves to lubricate the engine and thus protects important components (such as the valves). On the other hand, the oil provides cooling for the engine. As with a motor vehicle, the oil quality decreases over time, so that the lubricating and cooling properties deteriorate. If the oil looks dark or gritty or if it’s already low, then change the oil. Always follow the manufacturer’s recommendations about the type of oil.
Maintain air filter
The air filter has a direct influence on the function of the engine. Excessive contamination can lead to the engine getting less air – performance deficits and increased fuel consumption would be the result. Remove the filter and tap it gently to dislodge loose dirt, or use compressed air for reusable filters. If the filter is too dirty or damaged, replace it with a new one and make sure it’s positioned properly before securing the housing.
Maintain spark plugs
For trouble-free operation of the generator, the spark plug must be free of deposits and the electrode gap must be set correctly. Inspect the electrode for carbon buildup or wear, then clean any deposits with a wire brush. When replacing, care must be taken to ensure that suitable spark plugs are used so as not to cause damage to the generator.
To keep track of all these tasks, it’s recommended to use a generator maintenance checklist that’s tailored to your specific equipment. We’ve curated some checklists that you can easily reference and edit, depending on the type of generator you have.
Common generator issues
Here’s a quick guide to some issues that you might encounter as you inspect your generator:
Fuel leaks
How to spot: Check under the generator for any puddles or stains on the ground. The generator casing might also have some wetness or dampness. There might be a pungent gasoline or diesel smell, especially near the fuel tank, lines, and connections.
Causes: Over time, the fuel lines that carry gasoline or diesel to the engine can become worn, cracked, or brittle. Loose connections in the fuel system are another frequent cause of leaks. If the fuel tank itself is cracked or damaged, then fuel will freely leak out.
Risks: Leaking fuel, especially gasoline or diesel, is highly flammable and can cause a fire or explosion. There’s also less fuel available for the generator, so its performance is affected.
How to fix: Replace any damaged fuel lines immediately, tighten all loose connections, and repair or replace the fuel tank if cracks are found. With regular maintenance of the generator, you can prevent leaks.
Battery failure
How to spot: If the generator struggles to start or doesn’t start at all, this could indicate a weak or dead battery. You may also notice dim lights on the control panel or a clicking noise when trying to start the generator. Upon inspection, the battery terminals might show signs of corrosion—white powder around the connections.
Causes: Batteries lose charge over time, especially if the generator isn’t used often. It might also be caused by corrosion on the terminals or loose or damaged connections, which prevent the battery from charging properly.
Risks: The generator won’t be able to start, leaving you without backup power during critical times.
How to fix: Test the battery voltage with a multimeter to confirm if it holds a charge. If it’s low, try charging the battery. Otherwise, it’ll need to be replaced.
Clogged air filter
How to spot: If there’s a decrease in generator performance, such as reduced power output or increased fuel consumption, this might mean a clogged air filter. The engine might also struggle to run smoothly, or the generator might overheat. When you inspect the filter, it’ll be dirty.
Causes: Air filters gradually accumulate dirt, dust, and debris, especially if it’s outdoors, which is why filters should be cleaned or replaced regularly.
Risks: A clogged air filter restricts the flow of air inside the generator, leading to poor fuel efficiency, loss of power, and increased engine strain.
How to fix: Remove the air filter, then blow dust out with compressed air. For filters that are washable, clean them with soapy water and allow them to dry completely. If the filter is already beyond cleaning, replace it with a new one.
Oil leaks
How to spot: Look for oil puddles or slick spots underneath the generator or around the engine area. The engine or surrounding components might look greasy, and there might be a drop in oil levels.
Causes: Oil leaks usually happen because of worn or damaged gaskets and seals around the engine or oil pan. The bolts might also be improperly tightened, or the oil pan might be cracked.
Risks: With low oil levels, the engine might overheat or get undamaged. If not solved promptly, oil leaks can result in severe engine wear and even failure.
How to fix: Identify the source of the leak by inspecting gaskets, seals, and the oil pan, then repair or replace any of the problematic parts. After repairs, refill the engine with oil and check if it’s still leaking.
Benefits of regular generator maintenance
Here are advantages of regular maintenance of the generator at a glance:
- Damage is detected early and repaired cost-effectively. Catching problems such as leaks, worn components, or blockages early can prevent major system failures down the line.
- Life of the generator is extended. With consistent maintenance, all components of the generator are operating at their best, reducing wear and tear over time.
- Reliability and efficiency are maximized. Power supply can be continuous during power outages, with no unexpected failures.
- Preventive maintenance at rest for operational readiness. This is especially important in environments where reliable backup power is critical, such as hospitals or data centers.
- Environment is protected through reduced air pollution. A properly maintained generator produces fewer harmful emissions and burns fuel more cleanly.
Advantages of a mobile app for generator maintenance
Using a checklist for a power generator during maintenance makes the work more efficient and time-saving. All inspection items can be worked through in order one by one and nothing will be forgotten. In addition, maintenance checklists make it easier to keep and document the maintenance schedule.
However, you don’t just have to use paper checklists. In fact, those who rely on paper-based inspections quickly struggle with the problem of missing audit reports and documentation logs. Losing the history of a generator’s readings, parameters and damage is problematic and leads to duplication of effort. Replacing paper checklists with a reliable mobile inspection app like Lumiform simplifies using maintenance recording and inspection checklists, and planning for future maintenance intervals.
With Lumiform, maintenance teams can:
- Generate real-time data on maintenance. This makes the quality and reliability of maintenance measurable and constantly optimizes processes based on the data.
- After maintenance, generate reports automatically – this saves complete follow-up.
- Increase efficiency of internal processes: more efficient communication within the team, with third-party vendors, and with management, as well as faster incident reporting, means that any damage that occurs is resolved up to 4x faster.
- Continuously improve quality and safety. Through the flexible form builder, you can constantly optimize maintenance work and processes.