Why Preventative Maintenance Isn’t Optional

You may think your commercial generator is “working just fine,” until the moment it isn’t. When a power failure hits, there are no second chances. Facilities in healthcare, data centers, logistics, manufacturing, and education depend on backup power systems to maintain safety, operations, and compliance. But even a high-quality generator, left unchecked, can fail.

That’s where preventative maintenance (PM) comes in. Think of it as an insurance policy against downtime. In the first part of this three-part guide, we’ll break down what generator PM really means, what your plan should include, and why it’s the most cost-effective form of risk management your facility can invest in.

How Cost-Effective Is Preventative Maintenance? A Real World Scenario

Preventative maintenance isn’t just a checklist, it’s a safeguard. Here’s a real-world example:

During a routine inspection, a technician noticed the cooling system was overdue for its three-year service interval. A quote was sent, but the customer declined. On subsequent visits, the service was again recommended, but never approved.

Fast-forward to July 4th weekend, a full year later: a power outage triggered the emergency generator to start. Fifteen minutes later, a coolant hose ruptured, spraying fluid across the parking lot and disabling the generator.

What followed was a costly scramble: emergency after-hours service, expedited part shipping, a temporary rental generator, and a full coolant system service. What could have been a $3,000 proactive maintenance task ballooned into a $10,000 emergency repair.

This wasn’t just expensive. It could have jeopardized the facility’s safety and compliance.

What Is Preventative Maintenance for Generators?

Preventative maintenance refers to the scheduled inspection, testing, and servicing of your generator to ensure it’s always ready to operate under load. Unlike corrective maintenance (which fixes a problem after it happens), PM aims to detect issues before they lead to failure.

Most leading standards support preventative strategies, including:

• • NFPA 110 for standby power systems in critical facilities
  • NETA standards for electrical testing
  • OEM guidelines provided by manufacturers such as Generac, Kohler, and Cummins

Core Components of a PM Program

Every generator is different, but a good maintenance plan should always include:

• • Routine Inspections: Weekly or monthly visual checks for leaks, corrosion, and fluid levels, with deeper quarterly and annual inspections based on OEM requirements
  • Load Testing: Ensures the generator can perform under stress, using resistive and reactive tests
  • Fluid Changes: Oil and filter replacement, coolant flushes
  • Fuel System Checks: Removes sediment and water; includes fuel polishing for diesel systems
  • Battery Maintenance: Voltage checks, terminal cleaning, load testing
  • Exhaust and Control System Testing: Verifies emissions compliance and runs diagnostics on digital panels

Who Should Be Performing PM?

While in-house teams can handle some visual checks, most generator maintenance should be performed by:

• • Factory-certified technicians
  • EGSA (Electrical Generating Systems Association) certified professionals
  • Technicians with make/model-specific diagnostic tools

Working with a qualified third-party vendor can also help protect your warranty.

Common PM Mistakes

Even organizations that invest in preventative maintenance sometimes misstep:

• • Skipping Load Tests: Like owning a fire extinguisher but never testing it
  • Delaying Critical Replacements: Waiting for failure instead of following proactive schedules
  • Using Generic Checklists: Maintenance should be tailored to your environment and equipment specs

Documentation Matters

It’s not enough to perform maintenance:-you must document it. Proper records are critical to:

• • Meet NFPA, OSHA, and local code requirements
  • Demonstrate due diligence in audits or insurance claims
  • Inform long-term budgeting and lifecycle planning

Ask your service provider for:

• • Detailed logs
  • Battery and fuel test results
  • Before/after photos of key components

The ROI of a Strong PM Plan

Preventative maintenance pays for itself by:

• • Reducing emergency repair risk
  • Extending generator lifespan
  • Enhancing resilience during outages and storms

Don’t wait for a failure to force your hand.

What Next?

Your generator is only as reliable as the maintenance plan behind it. If you’re uncertain whether your PM program is truly protective, or if you’ve ignored recent service recommendations, now is the time to act.

Coming in Part 2: We’ll dive into which parts of your PM plan are essential, and which ones may be just “nice-to-haves.”

Need help assessing your current strategy? Contact us today to schedule a complimentary PM review.