Generators are commonly used as backup or emergency power supplies, providing an alternate power source during outages. Because they are often used infrequently—unless relied upon daily—some issues may go unnoticed. As generators age, the risk of mechanical failure increases if regular servicing is neglected.

 

Routine inspections can identify most problems, but not all generator users prioritize maintenance. Consequently, issues can arise that limit or stop a generator's power production, leading to failure. When this occurs, an emergency inspection by a technician is necessary.

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Emergency inspections typically uncover one of seven issues:

1. Battery Failure: The most common cause of generator failure, often due to loose connections or sulfation buildup. Sulfation occurs when lead sulfates in the electrolyte coat the battery’s lead plates, inhibiting electrical conversion and preventing the battery from starting the generator.

2. Insufficient Coolant: Generators shut down when overheated. Without enough coolant, a generator cannot operate for extended periods, risking failure when needed most.

3. Fuel Leak: Detectable by odor during regular maintenance, fuel leaks can result from a malfunctioning fuel pump or broken fuel line.

4. Oil Leak: Caused by wet stacking, where oil, fuel, and other liquids accumulate in the exhaust pipes due to carbonized fuel injection tips and faulty crankcase breathers releasing excess oil.
5. Control Setting Errors: Generators may fail to start if controls are left on incorrect settings after maintenance or testing. Incorrect resetting procedures following a fault shutdown can also cause control errors.

6. Fuel Bleed Back: Occurs when fuel returns to the generator’s tank instead of reaching the engine, often due to air in the injection mechanism or faulty check valves, making the generator behave as if it were out of fuel.
7. Empty Fuel Tank: An insufficient fuel level causes the pump to draw air into the system, which can lead to catastrophic engine damage as fuel injectors deliver less fuel into the cylinder, causing detonation. Stuck or faulty fuel gauges can also incorrectly indicate an empty tank.

The best way to avoid emergency situations is through regular inspection and maintenance of generators.

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