Project Title: Targeted Thermal Repair: Extending Asset Life at a Remote Site
Location: Macclenny, Florida
Client Sector: Telecommunications Infrastructure
Equipment: 60kW Olympian Diesel Generator (Model D60P4S)
Service Category: Critical Component Repair & Preventative Maintenance
1. The Challenge
A remote cellular tower in Macclenny, Florida, was relying on a 60kW Olympian generator for backup power. The unit began reporting erratic temperature data to the Network Operations Center (NOC).
While the generator was still technically functional, the unreliable data posed two major risks:
- False Positives: The system could trigger a safety shutdown during an actual outage due to a sensor error, dropping the tower offline.
- Blind Spots: If a real overheating event occurred, the control panel might fail to register it, leading to catastrophic engine destruction.
2. The Generator Source Solution
Rather than condemning the older asset or recommending a costly engine overhaul, Generator Source deployed a technician to perform a surgical, component-level repair.
Phase 1: Precision Diagnostics
Our technician arrived on-site and isolated the issue to the thermal monitoring circuit. The diagnosis confirmed that the engine block was healthy, but the “eyes and ears” of the system—the sender and thermostat—were failing.
Phase 2: Targeted Repair
We executed a targeted replacement of the specific failing components:
- High Engine Temp Sender: Removed the faulty sensor and installed a new OEM-spec sender to ensure accurate data transmission to the Zenith 150A Transfer Switch and remote monitoring systems.
- Thermostat Replacement: Replaced the aging thermostat to guarantee precise regulation of coolant flow, ensuring the Perkins engine maintained optimal operating temperature under load.
Phase 3: Verification & Service
Once the repair was complete, we didn’t just leave. We performed a full PM Service & Inspection to verify the rest of the system was up to standard. This included verifying that the new sensors were communicating correctly with the ATS and that the unit held steady temperature under test conditions.
3. The Results
- Cost Avoidance: By identifying and replacing only the $50–$200 components, we saved the client the $20,000+ cost of a premature generator replacement.
- Data Integrity: The NOC now receives accurate, reliable thermal data from the site, allowing for confident remote monitoring.
- Extended Lifespan: The repair and accompanying PM service extended the operational life of the 60kW unit, keeping it in the fleet and ready for the next hurricane season.
“We don’t just swap engines; we fix them. Our ability to troubleshoot down to the sensor level saves our clients thousands in unnecessary capital expenditure.”