Common Replacement Generator Parts & Components
The most common parts that typically need to be replaced on a commercial generator are (in no particular order):
- Batteries
- Oil & Oil Filters
- Air Filters
- Fuel Filters
- Belts and Hoses
- Coolant and Cooling System Components
- Engine Block Heaters
The above video featuring Duthie Power Generator Technician Jack Greenberg explains what to look out for and how to maintain these critical generator parts. In general, oil filters, fuel filters and oil should be changed annually while belts, hoses, coolant and thermostats are going to be replaced on an as-needed basis or every 3 years.
Below we go into detail on each component to help you ensure the longevity of your emergency power supply system.
Understanding and Maintaining Key Parts of a Commercial Generator
Commercial generators are critical assets for businesses, providing a reliable power source during outages and ensuring operations run smoothly. As any facility manager will tell you, understanding the most common parts of a generator that require replacement and how to maintain them can significantly extend the life of your equipment and prevent unexpected downtimes. This blog highlights the essential components frequently replaced in commercial generators and provides maintenance tips to keep them in optimal condition.
Generator Batteries
- Role: Generator batteries are crucial for starting the generator and powering control systems. Without a functioning battery, the generator cannot start.
- Common Issues:
- Battery failure due to sulfation (crystallization of lead sulfate).
- Loose or corroded connections.
- Battery age, typically requiring replacement every 2-3 years.
- Maintenance Tips:
- Regularly inspect and clean terminals to prevent corrosion.
- Check the electrolyte levels (for wet-cell batteries) and top up with distilled water if necessary.
- Ensure the battery is fully charged; undercharging can reduce battery life.
- Replace batteries proactively based on manufacturer recommendations or after frequent testing.
Generator Oil and Oil Filters
- Role: Oil lubricates the engine’s moving parts, reducing friction and wear. The oil filter removes contaminants from the oil, preventing engine damage.
- Common Issues:
- Degraded oil can lead to increased engine wear and overheating.
- Clogged oil filters can restrict oil flow, causing lubrication issues.
- Maintenance Tips:
- Follow a regular oil change schedule based on the manufacturer’s guidelines or after a specified number of operating hours.
- Replace oil filters with every oil change to ensure optimal filtration.
- Use the correct type and grade of oil as specified by the generator manufacturer.
Generator Air Filters
- Role: Air filters prevent dust, dirt, and other contaminants from entering the engine’s combustion chamber, which can cause damage and reduce efficiency.
- Common Issues:
- Clogged air filters can lead to reduced airflow, causing the engine to run rich and potentially overheat.
- Poor air filtration can result in increased engine wear and reduced lifespan.
- Maintenance Tips:
- Inspect air filters regularly, especially in dusty environments.
- Replace air filters according to the manufacturer’s recommendations or if they appear dirty or damaged.
- Ensure proper fitting and sealing when installing new filters to avoid unfiltered air bypassing the filter.
Generator Fuel Filters
- Role: Fuel filters remove impurities from the fuel before it enters the engine, protecting the fuel injectors and ensuring efficient combustion.
- Common Issues:
- Clogged fuel filters can restrict fuel flow, leading to engine misfires, reduced power, and stalling.
- Contaminated fuel can cause filter clogging and other engine issues.
- Maintenance Tips:
- Replace fuel filters at intervals recommended by the generator manufacturer or after a specified number of operating hours.
- Regularly inspect the fuel system for signs of leaks or contamination.
- Use high-quality fuel and consider additives to prevent microbial growth in the fuel system.
Generator Belts and Hoses
- Role: Belts drive various engine components, such as the alternator and cooling fan, while hoses transport fluids like coolant and fuel.
- Common Issues:
- Belts can wear, crack, or slip, leading to reduced efficiency and potential failure of driven components.
- Hoses can become brittle, crack, or develop leaks, leading to fluid loss and overheating.
- Maintenance Tips:
- Inspect belts and hoses regularly for signs of wear, cracking, or leaks.
- Replace belts if they appear worn or stretched.
- Ensure hoses are secure and free of leaks; replace if damaged or aged.
Generator Coolant and Cooling System Components
- Role: The cooling system, including coolant, radiator, and water pump, regulates the engine temperature, preventing overheating.
- Common Issues:
- Low coolant levels or contaminated coolant can lead to overheating.
- Radiator and water pump failures can result in inadequate cooling.
- Maintenance Tips:
- Check coolant levels regularly and top up with the appropriate type of coolant.
- Flush the cooling system and replace the coolant at intervals recommended by the manufacturer.
- Inspect the radiator and water pump for leaks, corrosion, and proper operation.
Engine Block Heaters
- Role: Engine block heaters preheat the engine in cold weather, facilitating easier starts and reducing wear.
- Common Issues:
- Failure to maintain can lead to difficult starts in cold conditions.
- Malfunctioning heaters can cause insufficient preheating.
- Maintenance Tips:
- Regularly test the heater for proper operation, especially before winter.
- Inspect the heater and its power connections for wear or damage.
- Replace the heater if it shows signs of failure or reduced efficiency.
Regular maintenance and timely replacement of key generator components are vital to ensuring the reliability and longevity of your commercial generator. By understanding these critical parts and their common issues, facility managers can take proactive steps to maintain their generators, minimize downtime, and protect their investment. Always consult the generator’s manual and follow the manufacturer’s guidelines for maintenance schedules and procedures.
For more information on what might go wrong with a commercial generator or any questions about generator replacement parts, request a quote or give us a call at 1-800-899-3931.
