LinkedIn’s Facilities Management Group (68,000+ members) recently asked the question “What are the most common diesel generator failures that you have come across?”. There were close to 200 responses that stated or implied 50 different reasons. Here they are:
Top 5 (referenced most)
- Preventative Maintenance Poor or Non-Existent
- Batteries Low or Dead
- Load Bank Test Not Done (some recommend 2 times a year)
- Remote Monitoring Non-Existent
- Routine Inspection/Check Not Done Regularly
Management Specific (alphabetical order)
- Facilities Management Poor/Non-Effective
- Human Error
- Maintenance/Service Records Poor or Non-existent
- Neglect
- NFPA 110, Chapter 8, 2013 edition Procedures Not Followed
- Plan Preventative Maintenance (PPM) or Maintenance Program is Poor or Non-existent
- Routine Inspection/Check Logging Poor or Non-existent
- Routine Inspection/Check Not Done Daily
- Routine Inspection/Check Not Done Thoroughly Every Time
- Routine Inspection/Check Procedure Poor or Non-existent
- Routine Inspection/Check Records Poor or Non-existent
- Service Contractor Not Competent
- Service Techs/Engineers Not Rotated Regularly
- Service Techs/Engineers Poor/Not Effective
- Shortcut Repairs to Reduce Spending
- Surprise Audits Non-Existent
- Training Poor or Non-Existent
Equipment Specific (alphabetical order)
- Automatic Transfer Switch (ATS) Exercising Not Done
- Automatic Transfer Switch (ATS) Failure
- Batteries Too Hot
- Battery Charger Broken
- Battery Charger Fuses Blown
- Battery Contacts Corroded
- Battery Life Ended
- Bird Nests & Mud Daubers Clogging Air Intakes and Vents
- Block Heater Broken
- Coolant Level Low
- Drive Belt Broken
- Exercising Not Done or Auto Exercising Not Working
- Fuel Dirty
- Fuel Filters Blocked/Plugged
- Fuel Line Broken
- Fuel of Wrong Type Accidentally Used
- Fuel Polishing/Cleaning Not Done
- Fuel Stored Too Long
- Fuel Tank Low or Empty
- Fuel Testing/Checking Not Done
- Full Building Shutdown Tests Not Done
- Hose Broken
- Moisture in Fuel (common in humid and rainy areas, and situations susceptible to condensation)
- Oil Changes Not Done Per Manufacturer’s Recommendations
- Sump Heater Broken
- Water Filter In Diesel Fuel Lines Not Changed Regularly (some recommend every 6 months)
- Water Filter In Diesel Fuel Lines None Existent (see Moisture In Fuel)
- Water Heater Element Is Not Adequate (prevents generator won’t start in cold climate)