Why a Generator Overhaul May Be the Smartest Move for Your Organization

A generator is one of the most important pieces of machinery in your organization. In many industries, an outage can easily lead to safety concerns, operational downtime, and potentially severe financial losses. However, like all mechanical systems, this crucial piece of equipment will decline in efficiency over time. While regular maintenance can help a generator achieve its maximum lifespan, there will come a point where an overhaul of the system will be the most sensible solution. There are telltale signs when this day has come.

Excessive Operating Hours

Most industrial-grade generators are designed to last between 10,000 and 30,000 operational hours, depending on factors such as maintenance, load usage, and operating conditions. Once the machine has exceeded this limit, the odds of a mechanical failure become increasingly likely. If your generator is approaching this threshold and you have noticed a decline in performance, it may be a sign to replace the system.

Declining Performance

A generator showing a decline in performance is one of the clearest signs that a serious overhaul is needed. A machine that struggles to start, runs inconsistently, or fails to support a full electrical load is demonstrating a major need for repairs and a system overhaul. Minor issues can generally be fixed with maintenance or a simple recalibration, but persistent issues should be seen as a red flag, trending towards a total overhaul as the solution.

Frequent Breakdowns or Repairs

Frequent breakdowns and repairs are not only the sign of an unreliable machine; they can quickly become a financial burden or even a legal liability. Rebuilding the system may be a more cost-effective solution than continuing to pour resources into an aging machine.

Visible Wear and Tear

In truly severe cases, it may be possible to see physical signs that a generator is reaching the end of its life cycle. Excessive smoke, oil leaks, coolant leaks, corroded parts, or worn belts and hoses all point to aging equipment. More than one system showing signs of wear at once can indicate that the internal components of the engine are heavily compromised as well. At that point, repairs do not make economic sense; purchasing a new generator is necessary.

Changing Operational Requirements or Expert Recommendation

It's possible that your facility's power demands have increased to the point where your current system can no longer efficiently or safely handle them. If your system is struggling to keep up with new equipment installations, then an overhaul makes the most economic sense. Additionally, experts in your facility or the manufacturer of the device may recommend that as the best course of action when a machine can no longer keep up with operational requirements.

Only Trust the Best – Overhaul with Gen-Tech

At Gen-Tech, our trained power generation professionals have decades of experience and possess the skills necessary to help a variety of industries best meet their power generation needs. If your generator systems are in need of an overhaul, don't delay. Contact us today to help design the best system for your facility's needs.