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Common Industrial Generator Performance Problems

Common Industrial Generator Performance Problems &Raquo; Illinoiselectricworks 328238 Employee Industrial Generator Image1

Industrial generators help mitigate the impact of power outages and ensure companies always retain power. These machines seamlessly integrate into a facility’s infrastructure, making their reliable performance non-negotiable. However, even the most significant systems are not immune to issues.

Any business owner or manager who relies on generators must know how to identify hiccups during operations and fix them right away. Learning about the typical performance problems of industrial generators will help you maintain operational efficiency and extend the service life of this critical power supply system.


Overheating is prevalent in industrial generators, often resulting from inadequate cooling or excessive load. Generators produce a significant amount of heat during operations, and when the cooling system fails to dissipate it, temperatures rise and can lead to damage. Regular cooling system maintenance and operating within recommended load limits can mitigate this risk.

Fuel System Issues

Fuel system problems, from leaks and contamination to improper fuel usage, can negatively impact a generator’s performance. Contaminated fuel can lead to clogs and blockages in the fuel filters and injectors, reducing efficiency and potentially causing complete system failure. Regularly inspecting for leaks, using high-quality fuel, and choosing storage conditions that minimize contamination can help you avoid these issues.

Wet Stacking

This situation typically arises when the generator operates at low load levels for extended periods, preventing the engine from reaching the necessary temperatures to burn fuel. Wet stacking in industrial generators reduces efficiency and could cause long-term damage to the engine and exhaust system. Addressing this problem involves periodically running the generator at high loads or installing a load bank to increase the load during operation artificially.

Battery Failure

The battery is a critical component of an industrial generator, serving as the source of power that starts the engine. Battery failure, often caused by aging or the accumulation of lead sulfate crystals on the plates, can render a generator inoperative. Maintaining adequate charges, storing batteries in a suitable environment, and regular testing can extend battery life and reliability.

Alternator Failure

The alternator converts mechanical energy into electrical power, and its failure can lead to no power output. Causes of alternator failure can include bearing failure, winding faults, and overheating. To prevent such issues, keep the alternator in good condition and conduct regular inspections for wear and tear. Also, adequate cooling should be provided to avoid overheating.

Understanding industrial generators’ common performance problems allows operators to avoid them, proactively ensuring they remain reliable and effective. A well-maintained generator is an investment in your business’s sustainability and success.


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Originally Published on

Michael Levitt Chief Burnout Officer

Michael D. Levitt is the founder & Chief Burnout Officer of The Breakfast Leadership Network, a San Diego and Toronto-based burnout consulting firm. He is a Keynote speaker on The Great Resignation, Quiet Quitting and Burnout. He is the host of the Breakfast Leadership show, a Certified NLP and CBT Therapist, a Fortune 500 consultant, and author of his latest book BURNOUT PROOF.

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