5 Common Reasons Industrial Generators Fail

Is your industrial generator not working as expected? Perhaps it is struggling to power up, or maybe it is failing to turn on completely. Without a properly working generator, you put your business at risk. Power outages are on the rise in California, and you don’t want to be left in the dark should the unexpected happen. A prolonged blackout can cause your company thousands, or even tens of thousands, of dollars in lost production.

At Valley Power Systems, we want to help our customers avoid unnecessary downtime and protect their bottom line. Knowing the reasons your generator could be malfunctioning can help you address the issue before the next power outage occurs. Here are five of the most common generator issues.

1. Battery Malfunctions

Battery problems are a frequent culprit when industrial generators fail. Various factors can adversely impact battery performance, such as loose wires or rusted connections. In this case, your generator technician will simply need to tighten or replace the wires or connections to get your system working again.

Also, it is important to note that generator batteries are only designed to last around three years before they need to be replaced. If yours is approaching this age, it could cause your system to act unpredictably. Additionally, lead sulfates can build up on battery plates over time, especially if the battery is frequently undercharged. This can impede the electrical flow and significantly disrupt battery performance. At this point, battery replacement is likely in order.

It is essential to ensure that your battery is inspected at each maintenance check. This will help you maintain power system reliability as well as extend the lifespan of your battery.

2. Leaks in the System

Another reason that your generator could be failing is it could be leaking oil, fuel, or coolant. These leaks are quite common, but they can be difficult to catch at first because they tend to begin as a small leak that progresses over time. You may not know that you have a leak on your hands until it is too late. Leaks can make your system work harder than necessary to perform the same job. This results in lost efficiency, excessive wear and tear, and increased energy expenses. If the leak persists, your system could become damaged beyond repair, reducing its expected lifespan. A relatively minor issue has now become a huge, expensive problem for you.

To keep leaks at bay, you should have a generator maintenance technician inspect your unit at least quarterly. They will have the proper tools and knowledge to detect hidden leaks and repair them before they have a chance to present with you a major problem.

3. Overheating the Engine

Overheating is another common cause of industrial generator failure. Your power system can overheat due to numerous reasons, including:

• Low coolant levels
• Worn, cracked, or clogged hoses
• Clogged air filters, leading to dirt in the engine
• Overloading the generator
• Low oil levels
• Broken cooling fan
• Clogged fuel injectors

When your generator experiences one or more of these issues, it is forced to work harder than usual to perform. It can also cause substantial damage to the engine, such as burning out the alternator, warping the rotor, melting the bearings, blowing out the head gasket, and damaging the exhaust system, among other issues. These repairs can be quite costly, and in some cases, a generator replacement will be required.

You’ve made a significant investment in your generator, so you don’t want to have to buy a new one any sooner than necessary. The best way to prevent overheating is to stick to your maintenance schedule year-round. Your generator technician will ensure that all fluids are at the proper level, change the air filters, repair broken hoses and fans, and much more. Also, you should remember not to exceed the capacity of your power system during operation. Doing so will eventually overheat the engine, reduce its efficiency, and ultimately shorten the lifespan of your equipment.

4. Extensive Water Damage

Water exposure can be detrimental to engine health. If your generator is subjected to excessive moisture, rust can begin to accumulate outside the unit. This can eventually corrode electrical connections, resulting in power failure. Additionally, if water travels inside the engine, its various parts can rust and corrode, causing significant engine damage. You can prevent water exposure by investing in a waterproof enclosure for your unit. This will reduce the impact of adverse weather, keeping your system nice and dry throughout the year. You should also remember never to spray water on or near the generator. If your generator needs cleaning, it is always best to let a professional handle the job to minimize the risk of rust and corrosion.

5. Poor Generator Maintenance

Preventative maintenance is key to keeping your system operating at its best. If maintenance is neglected, your power system will be at much higher risk of failing prematurely. For example, putting off oil changes for too long can lead to increased wear and tear and overall reduced efficiency for the unit. Your system needs fresh oil to properly lubricate all the moving parts of the engine. Additionally, not changing filters enough can cause dirt and debris to build up, which will restrict airflow and put stress on your engine. Additionally, without a clean filter, dirt could enter the engine, which can cause a host of problems, including overheating. This can have a negative impact on the unit’s lifespan. Filters should be checked at every maintenance check and changed out regularly to maximize airflow.

These are just a few of the maintenance tasks that are imperative to ensure the reliability of your system. With customized maintenance packages available, you can count on Valley Power Systems to maintain and service your generator on your schedule. Along with taking care of maintenance, we will perform a complete assessment to ensure that there are no hidden issues with your system. This will allow you to address issues before they progress, helping you avoid a generator breakdown later. Knowing that your generator will work when you need it most will provide you with great peace of mind.

Your Partner in Power

You can avoid these common generator issues by working with Valley Power Systems for all your maintenance needs. Our family-owned and operated business has been providing reliable power solutions in California since 1949, and we look forward to becoming your partner in power.

Whatever problem your industrial generator is having, you can trust our highly trained and experienced technicians to get to the bottom of it. We will perform a complete assessment, offer cost-effective options for repair, and handle the job for you promptly. Our goal is to keep your power system up and running throughout the year so that it’s ready when and where you need it most.

When it comes time for a new unit, we are factory authorized to offer some of the most trusted and reliable power equipment brands in the industry, including Blue Star Power Systems and Atlas Copco. We also offer generator rental for short-term projects.

Contact Valley Power Systems today to learn more about our professional generator services.

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