What Field Service Teaches Us
When it comes to industrial and commercial backup power, reliability isn’t optional. Yet many of the emergencies our field service teams respond to each week could have been prevented with proper maintenance and planning.
Across our service regions in Colorado, Florida, and Texas, certain problems show up again and again. By understanding these common issues — and why they happen — businesses can take proactive steps to reduce costly downtime and emergency calls.
Here are the top generator service issues our technicians encounter in the field and what they reveal about preparedness.
1. Fuel Contamination
Fuel systems are one of the most frequent points of failure we see. Even when the generator itself is in excellent condition, contaminated fuel can shut it down in seconds.
Common causes include:
- Water intrusion from condensation, rain, or poorly sealed tanks.
- Microbial growth (“diesel bug”) that feeds on water in fuel tanks.
- Sediment and sludge buildup from long-term storage.
Why it matters: A clogged fuel filter or injector means the engine starves under load, causing stalls, sputtering, or complete shutdowns during an outage.
Prevention strategies:
- Regular fuel testing and polishing to remove contaminants.
- Ensuring tanks are sealed, vented, and compliant with UL standards.
- Coordinating a refueling plan with trusted suppliers, especially ahead of storms.
📍 Example from the field: A commercial property in Denver had a reliable Caterpillar 500 kW unit, but their tank hadn’t been inspected in three years. Sludge buildup would have stalled the engine during the next outage — our team drained, cleaned, and refilled the system before it became an emergency.
2. Battery Failures
Batteries may seem minor compared to a 2MW generator engine, but without them, the generator won’t start at all. In fact, weak or dead batteries are one of the most common reasons for service calls.
Typical problems include:
- Age and neglect: Batteries degrade faster than most facility managers expect.
- Corroded terminals: Loose or oxidized connections reduce current flow.
- Lack of testing: Batteries often sit untested until they fail during an outage.
Why it matters: During an outage, facilities expect instant backup power. A failed start sequence caused by dead batteries turns a reliable system into a liability.
Prevention strategies:
- Replace batteries every 3–5 years or sooner if tests show weak voltage.
- Perform regular load testing to ensure capacity.
- Keep connections clean, secure, and corrosion-free.
📍 Example from the field: A Florida hospital experienced a failure to start during a utility outage. The root cause? Corroded terminals on batteries that hadn’t been tested in over a year. Our team restored power, but preventative checks could have avoided the scare.
3. Starter and Control Issues
Another recurring issue our service teams encounter involves starter motors and control systems. Customers often report that the starter engages but the generator won’t fully turn over.
Common causes include:
- Worn starter motors that can’t provide enough torque.
- Faulty solenoids or relays preventing engagement.
- Control board failures that disrupt the start sequence.
Why it matters: These issues typically emerge at the worst possible time — when the grid fails and the facility needs power most. Troubleshooting takes longer without service history, stretching downtime.
Prevention strategies:
- Schedule routine starter inspections and replacements when wear is identified.
- Maintain complete service logs to help technicians diagnose faster.
- Test start sequences during load bank tests, not just idle runs.
📍 Example from the field: An industrial facility in Texas reported their Cummins 1250kW unit wouldn’t start during a planned test. Our team traced the issue to a faulty relay in the control panel — easily replaced, but avoidable with proactive inspection.
Why These Problems Are So Common
What unites these three issues — fuel contamination, battery failures, and starter/control problems — is that they are all preventable. They occur most often in systems that:
- Lack scheduled preventative maintenance.
- Have incomplete service records.
- Are rarely tested under full load.
The lesson is clear: reliability isn’t built during the outage, it’s built during preparation.
The Value of Preventative Maintenance
At Generator Source, we approach every generator service with the same mindset: prevention first. Our preventative maintenance programs are designed to address these common failure points before they become emergencies.
Our services include:
- Fuel testing, polishing, and tank inspections.
- Battery load testing and replacement.
- Starter and control system diagnostics.
- Full load bank testing to confirm performance under real-world conditions.
- Our 31-point inspection, performed by EGSA-certified technicians, covering every aspect of generator readiness.
Regional Realities for Colorado, Florida, and Texas
Different regions see different risks:
- Colorado: Winter cold strains batteries and fuel systems, making testing critical.
- Florida: Hurricanes create long outages and fuel delivery challenges.
- Texas: Extreme heat pushes systems to their limits and drives higher runtime hours.
Our regional service teams prepare for these conditions, ensuring generators are tailored to the specific risks businesses face.
Preparation Prevents Emergencies
The most common generator failures aren’t the result of rare breakdowns — they’re the result of missed maintenance. Fuel contamination, weak batteries, and starter/control issues account for a significant share of the emergency calls we answer.
The good news? Every one of these problems is preventable with the right maintenance program.
With over 50 years of experience, Generator Source has helped businesses across industries — from healthcare and manufacturing to data centers and property management — avoid downtime by staying proactive.
Call 877-866-6895 or visit generatorsource.com to schedule a preventative maintenance program for your facility.