Generator service questions.

NFPA 110 calls for a weekly inspection, a monthly exercise run of at least 30 continuous minutes at 30% or more of nameplate kW (or the manufacturer’s minimum exhaust gas temperature), monthly operation of each transfer switch, annual fuel quality testing, and, for Level 1 systems, a 4-hour run at least once every 36 months. The edition that applies is the one adopted by your local authority having jurisdiction, so confirm it with your AHJ.

Generators typically need full service annually or every 200 to 500 hours of operation, whichever comes first. We also recommend weekly visual checks and monthly exercise runs. A tailored plan can include breaker testing, fuel tank cleaning, and engine maintenance to prevent issues before they start.

The most common cause we find is a dead or weak starting battery, which is why batteries get tested monthly and replaced on a schedule. After that: contaminated fuel that clogs filters, a transfer switch that did not transfer, and coolant or block heater problems that keep a cold engine from starting. A generator that only runs under light load can also wet stack, leaving unburned fuel in the exhaust that chokes the engine when real load arrives.

A standard visit covers fluid checks (oil, coolant, fuel), filter inspections and replacements, battery testing, visual inspection for leaks or wear, control panel inspection, and system performance verification. Every visit ends with a written record of what was found and what was done.

NFPA 110 requires a written maintenance and testing schedule plus a permanent record kept on site and available to the authority having jurisdiction. Each entry should show the date, the technician, any unsatisfactory condition and the corrective action taken, parts replaced, and the results of testing after a repair. For exercise runs, the record should also capture engine hours, transfer times, voltage and amperage by phase, frequency, pressures, and temperatures. Hedgehog Power Systems delivers a written report after every visit that covers these fields.

Contaminants like water, sludge, and sediment clog filters, damage injectors, and cause failures during outages. Regular cleaning removes these contaminants, restores clean fuel flow, and extends engine life, which is critical for a standby system that sits idle most of the year. NFPA 110 also calls for stored fuel to be tested annually.

Yes. Hedgehog Power Systems services Cummins, Onan, Caterpillar (Cat), MTU, Kohler, Generac, Baldor, Briggs & Stratton, Aggreko, and many others. Our technicians handle diagnostics, repairs, upgrades, and maintenance for diesel, natural gas, and propane units.

Breaker testing verifies trip times, insulation, contact resistance, and fault handling under simulated conditions. It confirms that your generator and electrical system will protect equipment and personnel during overloads or faults. NFPA 110 also calls for Level 1 main and feed breakers to be exercised annually with the generator off.

Signs include low coolant levels, overheating during test runs, discolored or contaminated coolant, or worn hoses and belts. We offer tiered coolant service, Level 1 through 3, to replace components, flush the system, and prevent engine damage from corrosion or freezing.

An automatic transfer switch, or ATS, detects a utility power failure and switches a facility’s electrical load to the standby generator automatically, then switches back once utility power is stable. An aging or misconfigured ATS is one of the most common reasons a generator with a healthy engine still fails to deliver power during an outage. NFPA 110 requires each transfer switch to be operated monthly.

Yes. Hedgehog Power Systems dispatches for emergency diagnostics and repair when a standby unit fails to start or fails mid-outage, across Illinois and the surrounding states we serve. Call (708) 292-6300 for emergency response.