Generators are among the most essential items in almost every aspect of our lives. However, just like a car, they require regular maintenance to function flawlessly when needed. Whether you have a small model for your home or a stationary diesel generator at your workplace, neglecting regular generator maintenance can leave you stranded when you need it most.
What should the recommended maintenance interval be for a generator?
The most frequently asked question is when maintenance should be performed. Generator maintenance intervals are determined by two factors: Operating Hours and Time Interval. Generally, whichever comes first is applied.
Maintenance Based on Working Hours
For new generators, the first generator oil change must be performed after the initial 20-30 hours of use, which is the engine’s break-in period.
For portable gasoline generators, a general maintenance check (oil and filter check) is generally recommended every 50 to 100 operating hours.
For larger capacity diesel generators, this interval may vary between 150 and 250 hours, depending on the user manual.
Maintenance Based on Time Interval (Even If Not Used)
Even if your generator is not used, it should be run under load (with a device connected) for 15-20 minutes at least once a month. This charges the battery, lubricates the internal engine parts, and delays fuel deterioration.
Even if your generator hasn’t been used at all during the year, the engine oil, filters, and battery condition should be checked and replaced if necessary at least once a year. Oil that has been sitting idle can lose its properties.
Note: If the generator is operating in a very dusty, humid, or dirty environment, the maintenance interval should be shortened, and the air filter should be checked more frequently.
Oil is the lifeblood of the engine. Low oil levels can cause the engine to overheat and “seize” (complete engine failure).
Always check the oil level using the dipstick before starting the generator. Ensure the generator is on a level surface.
How to Change Oil?
We’ve already mentioned the importance of oil changes. Changing the oil is quite easy. You can easily do it by following the steps below:
Run the engine for 5 minutes to warm it up (to allow the oil to become more fluid).
Stop the engine and open the oil drain plug to drain the old oil into a reservoir.
If there is an oil filter, remove it and replace it with a new one (lightly apply new oil to the gasket of the new filter).
Close the plug and fill with new engine oil of the type specified by the manufacturer (e.g., 10W-30).
Check the level with the dipstick; it should not be too low or too high.
Air Filter Check (Generator Filter Cleaning)
A clogged air filter prevents the engine from breathing. This increases fuel consumption, reduces engine power, and causes black smoke to be emitted from the exhaust.
Remove paper filters and hold them up to the light. If dirty, gently tap them on a hard surface to remove dust. Never wash them with air or water. Replace them immediately if they are very dirty or torn.
Sponge filters are more suitable for generator filter cleaning. After washing them with soapy water and drying them completely, you can lightly moisten them with engine oil (if specified in the manual) and put them back in place.
The fuel filter filters dirt, rust, and water particles from the fuel coming from the tank, ensuring that clean fuel reaches the carburetor or injection system.
A clogged fuel filter causes the engine to misfire or not start at all.
Fuel filters are generally not cleaned; they are replaced with new ones during generator maintenance (usually once a year).
Maintenance Tips to Extend Generator Life
In addition to regular filter and oil changes, you should pay attention to the following recommendations to maximize the life of your generator:
Gasoline becomes stale and resinous if left for more than 30 days. This can clog the carburetor. If you will not be using the generator for a long time, add a “fuel stabilizer” to the tank or completely empty the tank and fuel line.
The battery is especially important in electric start generators. Monthly test runs keep the battery charged. Also, make sure the terminals are clean and free of corrosion (oxidation).
Keep the exterior of the generator, especially the air intake/outlet grilles, clean. Oily dirt and dust accumulating around the engine reduce cooling efficiency and lead to overheating.
Every generator has a maximum capacity (kVA/kW). Pushing the generator beyond its capacity overloads the alternator (the part that generates electricity) and the engine, which can lead to voltage fluctuations and permanent damage.
When not in use, the generator should be stored in a dry, well-ventilated place, and preferably covered.