The air intake assembly is a two-part critical system acting as the respiratory tract for your generator.

• The Air Inlet System: This includes the piping, hoses, clamps, rain caps, and housing that route outside air to the turbocharger. Its job is to maintain a sealed, airtight path to prevent “dusting” (unfiltered air entering the engine).

• The Air Filter: Sitting inside the housing, the filter media captures abrasive particulates (silica, dirt, carbon) and environmental contamination before they reach the combustion chamber.

Clean, unrestricted airflow is non-negotiable. A sealed system and a clean filter ensure Volumetric Efficiency—guaranteeing the engine gets the large, steady oxygen volume required for complete combustion, preventing wet stacking and turbocharger failure.

How often it should be inspected?

How often it should the air filters and system components be replaced?

Standard protocol is to replace air filters every 12 months. However, we utilize a “Condition-Based” approach for extreme environments—checking for restrictions, leaks, contamination, and overall condition, not just replacing based on hours. In dusty regions like Texas or the Southwest, filters may reach maximum differential pressure in less than 12 months. In humid Coastal Zones, moisture can swell the paper media, necessitating earlier replacement to prevent airflow starvation.

The System (Infrastructure): When Needed – The inlet piping, rubber elbows, and hump hoses are not replaced on a calendar schedule. They are replaced based on physical degradation. During our PM1, if we detect rubber hardening, stress cracks, or rusted housing, we recommend immediate repair to maintain system vacuum integrity.

• High Differential Pressure: The “Pop-up” restriction indicator on the housing trips to red.
• Filter Collapse: In severe cases, a completely clogged filter can collapse inward, creating a bypass condition that allows debris into the engine.
• Black Exhaust Smoke: Starved of air, the engine runs “rich” (too much fuel), creating unburned soot.
• Sluggish Load Acceptance: The generator struggles or stalls when the automatic transfer switch (ATS) applies the building load.
• Rough Running or Shutdown: Severe restriction can cause unstable RPMs or complete shutdown under load.
• Turbocharger Surging: Audible “woofing” or uneven RPMs as the turbo struggles to pull air.
• Visible Contamination: Fine dirt coating the inside of the intake piping (a sign of a system leak bypassing the filter).

“Can I just clean the air filter with compressed air instead of replacing it?”

No. We strongly advise against this. Blowing compressed air through an industrial filter often creates microscopic tears in the paper media. These invisible holes allow abrasive silica to pass directly into the engine cylinders, acting like sandpaper on your piston rings. It is cheaper to replace the filter than to rebuild the engine.