Generators are critical backup power solutions, but like any mechanical system, they require regular maintenance to function optimally. Below are some common generator faults and their possible causes, helping you troubleshoot and resolve issues efficiently.
One of the most common causes of generator failure is battery failure. In fact, 80% of all battery failures are due to sulphation build-up, which occurs when lead sulphates accumulate on the plates of lead-acid batteries. Regular battery maintenance, including testing and charging, is crucial to preventing this issue.
A low coolant level is often a sign of an external or internal leak. During routine inspections, look out for visible puddles of coolant around the generator. Addressing leaks promptly helps prevent overheating and engine damage.
What appears to be an oil leak may actually be a case of 'wet stacking' or 'engine slobber.' This occurs due to excessive no-load run time, leading to unburnt fuel and oil residues accumulating in the exhaust system. Checking for actual leaks versus wet stacking can save unnecessary repairs.
One of the simplest yet most overlooked reasons for generator failure is the control switch being left in the 'off' position instead of 'auto.' Human error is a common culprit, so always verify that the generator is set to automatic mode to ensure it starts during a power outage.
Modern generators, particularly those not run regularly, are more prone to air entering the fuel system. This issue arises due to tighter tolerances in fuel systems designed to meet modern emission standards. Running the generator periodically helps prevent air locks and ensures reliable startup.
Generators rely on fuel, and mechanical fuel gauges are not always accurate. Unlike a moving vehicle that circulates fuel, generator tanks remain stationary, causing fuel to settle. Periodic checks and accurate monitoring of fuel levels help prevent unexpected shutdowns due to fuel depletion.
To prevent overfilling, government regulations require fuel tanks to be equipped with high fuel level alarms. These alarms typically activate when the fuel level reaches 90% to 95% capacity. Ensuring these alarms function correctly can help avoid fuel spills and environmental hazards.
If the generator fails to start, check whether a remote emergency stop switch has been accidentally activated. Additionally, if a breaker trips after the automatic transfer switch (ATS), the generator will not engage. Inspect the ATS during power outages for status indicators showing switch positions and power availability. Always identify the root cause of a tripped breaker before resetting it.