Your generator is meant to be a backup power system that keeps operations running even during a power outage. However, it can't do that job if it isn't properly maintained. Implementing a structured preventive maintenance program is the best way to ensure that your generators come on when the power goes off. A well-executed maintenance schedule is not just about generator care. It ensures that it starts when you need it and extends the lifespan of your investment.
Monthly Maintenance Tasks: Building the Foundation
The cornerstone of any generator maintenance program is the monthly inspection. These allow you to identify potential issues before they become major problems. They should be performed by qualified technicians to ensure that all issues are caught.
Visual and Operational Inspections
● Examine the exterior for signs of corrosion or other damage.
● Check all mounting hardware to ensure that all bolts and other connectors are secure.
● Inspect the fuel system for leaks, paying closer attention to connections and filters.
● Investigate any fuel odors or visible stains immediately.
Fluid Level Monitoring
● Check engine oil levels, paying attention to any discoloration or contamination, as it may indicate internal wear.
● Verify all coolant levels and, if applicable, verify the correct mixture to provide adequate freeze protection and corrosion resistance.
● For models with hydraulic governors, also check the hydraulic fluid levels.
Battery System Maintenance
● Test the battery voltage, specific gravity, and its overall condition.
● Clean the terminals and apply a corrosion-resistant protective coating.
● Verify that battery chargers are working correctly.
Control System Testing
● Verify that all alarm systems properly activate.
● Check that the control panel displays accurate readings.
● Confirm smooth operation of automatic transfer switches.
● Test emergency stop functions and all safety interlocks.
Quarterly Generator Care: Deeper System Analysis
Quarterly maintenance goes beyond the basic inspections and starts a more comprehensive look at the system. Since these inspections are more involved and often require special tools, proper scheduling is important for them.
Load Bank Testing
This is one of the most important quarterly checks. The goal is to ensure that the generator is able to handle its rated capacity by running it under a controlled load that simulates actual usage. As a result, this test can reveal problems that no-load testing cannot. Fuel system problems, cooling issues, faulty electrical components, and other issues can be discovered during load bank testing.
Fuel System Maintenance
Rather than simply inspecting the fuel system, the quarterly maintenance procedure takes a closer look at the system. Any fuel filters due for replacement are swapped out for new ones. Because diesel fuel degrades over time, this is also the best time to ensure that the fuel is still of suitable quality if you have a diesel generator. For natural gas generators, gas pressure regulators are checked to make sure they're maintaining proper pressure.
Air System Service
Similar to fuel system service, now is the time to replace your air filters and give a good once-over to the entire intake system. Clogged air filters reduce the efficiency of the system and can damage the engine over time. If your generator has a turbocharger, also check its operation and listen for any unusual noises during this inspection.
Cooling System Maintenance
This is also the time to take a more thorough examination of the cooling system. Coolant concentration and pH levels should be checked, and the coolant replaced if needed. All radiators, hoses, and fans should be checked for proper operation without leaks or unusual noises. Finally, ensure that any belts have the proper tension and an acceptable amount of wear.
Annual Maintenance: Comprehensive System Overhaul
The most involved maintenance happens annually. This level represents an intensive level of preventive care. Often, specialized service providers are required, necessitating extended downtime scheduling.
Engine Performance Analysis
A qualified mechanic should take a detailed look at the engine, analyzing the compression, valve adjustment, and other major components. The process may require the removal of major engine parts to provide the most thorough check possible.
Electrical System Evaluation
This evaluation consists of a complete testing of all alternators, voltage regulators, and all of the generator's control circuits. At the same time, the insulation resistance should be checked to identify any potential electrical failures before they occur. While checking all electric components, be sure that each of their connections is torqued to specification.
Governor and Control System Calibration
The governor ensures that the generator is operating at the proper speed and voltage as load conditions vary. Inspection and calibration of this system often require specialized tools and test equipment, so it should be performed by qualified professionals.
Transfer Switch Maintenance
The transfer switch is what allows the generator to begin providing power to the building instead of the utility lines. Its annual inspection should include thorough testing of all automatic transfer equipment. This includes checking for contact wear and testing all protective relay functions.
Generator Care Implementation Strategy for Maintenance Supervisors
While this checklist provides a great basis for a generator care program, a solid strategy is what really makes or breaks your generator's lifespan. Establish clear documentation of procedures and document all maintenance activities with dates, findings, and changes.
If your maintenance is performed in-house, make sure your staff is properly trained and qualified for all of the procedures they'll be performing. Try to keep the most commonly replaced parts on hand, so you aren't waiting around for delivery if a problem is discovered.
If having a full maintenance team on staff is outside of your budget, Bay City Electric Works offers a comprehensive set of generator maintenance and repair services. To learn how we can help you keep your backup generator healthy, contact us today.
