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Load Bank Testing for Industrial & Commercial Generators 

Service Truck on Street with Load Bank Test

Load Bank Testing for Industrial & Commercial Generators

50+ years · Local Colorado Springs expers · All makes & models · In-stock parts · EGSA Certified Pros

Generator Source performs professional load bank tests to verify that your standby or prime power system can deliver rated power safely and reliably when it matters most. 

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        What Is a Load Bank Test? 

        A load bank safely applies a controlled, incremental electrical load to your generator and measures performance at each step. Our technicians simulate real-world conditions, typically at 25%, 50%, 75%, and 80%, to verify the unit’s capability, stability, and cooling capacity over time. 

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        Why Load Bank Testing Matters 

        A generator that starts is not the same as a generator that performs.
        • Power Rating: Confirms the unit can produce rated kW and maintain voltage and frequency stability under real demand.
        • Wet Stacking: Prevents wet stacking in diesel units by burning off unburned fuel and carbon.
        • Hidden Issues: Reveals hidden issues (cooling, fueling, controls) before an outage.
        • Compliance: Documents performance for audits, insurers, and compliance programs.

        What We Test & Verify

        • Electrical performance: voltage, frequency (Hz), phase balance, power factor 
        • Output stability: response to step-load changes, transient recovery 
        • Thermal behavior: exhaust temps by cylinder (IR checks), coolant temps, oil temps 
        • Mechanical health: vibrations, abnormal noise, leaks, belt condition 
        • Controls & protection: alarms, shutdowns, governor/AVR response, safeties 
        • Emissions health (diesel): soot and visible smoke reduction after full-load operation 
        • Deliverables: a signed Load Bank Report with all readings, observations, pass/fail notes, and recommendations. 

        Our Load Bank Testing Process 

        • Pre-test inspection: Visual checks, fluid levels, belts/hoses, battery and starter condition, fuel supply, and airflow.
        • Warm-up & baseline: Verify no-load voltage/frequency, governor and AVR baseline.
        • Step loading: Apply 25% → 50% → 75% → 80% load; hold each stage to stabilize and log readings.
        • Sustained full-load run: Prove continuous power delivery; monitor cooling/exhaust temps and engine response.
        • Step unload & recovery: Observe voltage/frequency recovery and protective device behavior.
        • Post-test inspection: Re-check leaks, connections, codes/alarms; review results with your team.
        • Report & recommendations: Detailed documentation plus prioritized action items (e.g., cooling service, fuel polishing,

        Common Issues a Load Bank Test Catches Early 

        Underfrequency/Undervoltage

        Underfrequency/undervoltage under load (governor/AVR tuning needed) 

        Fuel Starvation

        Fuel starvation from clogged filters or contaminated fuel 

        Wet Stacking

        Wet stacking from chronic low-load operation

        Load Bank Pass/Fail Criteria

        • Maintain rated kW at specified voltage and frequency with acceptable droop limits 
        • Hold phase balance within tolerance 
        • Sustain full-load temps without alarms or shutdowns 
        • Recover smoothly from step-load changes 
        • Failures trigger a corrective action plan, our technicians outline exactly what to fix and how urgent it is
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        Still have questions?

        Generator Source specializes in low-hour, used, new, and surplus generator sets. We have a wide variety of generator sizes and models to fit any project. We are not a broker, we own what we sell.
        Call us today (877-866-6895) or click Contact Us to be connected with one of our experienced sales reps. 
        We have 350+ generators in stock and ready to ship!

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        Still have questions or looking for more information?