The Cost of Neglect
Generator failures during power outages are almost always preventable. In our 18+ years of servicing diesel generators across Pakistan, Aiwa Powers has found that over 90% of emergency callouts could have been avoided with basic routine maintenance.
1. Run the Generator Under Load Monthly
A generator that sits idle for weeks develops wet stacking—unburned fuel and carbon deposits accumulate in the exhaust system. Run your generator at 50–75% load for at least 30 minutes every month.
2. Check Engine Oil Before Every Start
Low or degraded oil is the leading cause of engine seizure. Check the dipstick before every use and change oil every 250 hours or 6 months, whichever comes first. Use the grade specified in your owner's manual.
3. Inspect the Air Filter Monthly
A clogged air filter starves the engine of oxygen, reducing efficiency and increasing fuel consumption. Tap out dust monthly and replace the filter every 500 hours.
4. Test the Battery Weekly
Generator batteries discharge through self-discharge even when not in use. Test the battery voltage (should be 12.4–12.6V at rest) weekly and keep it on a float charger during storage.
5. Check Coolant Level and Condition
Low coolant causes overheating and catastrophic engine damage. Check the coolant reservoir monthly and flush the entire cooling system every 2 years, replacing with fresh antifreeze/coolant.
6. Inspect Fuel System for Leaks
Walk around the generator and inspect all fuel lines, fittings, and the tank for leaks or cracks before each start. Diesel leaks are a fire hazard and indicate worn seals.
7. Replace the Fuel Filter Annually
Diesel fuel picks up water and sediment from tanks. A clogged or water-contaminated fuel filter causes rough running and, eventually, injector damage. Replace annually or every 500 operating hours.
8. Keep the Generator Clean
Dirt and debris clog cooling fins and ventilation, causing overheating. Wipe down the exterior monthly and ensure a 1-metre clearance on all sides for airflow.
9. Test the Transfer Switch
If you have an automatic transfer switch (ATS), simulate a mains failure monthly to confirm the ATS switches the load correctly and the generator picks up within the specified time.
10. Schedule Annual Professional Servicing
Have a certified generator engineer inspect, load-test, and service the unit annually. Aiwa Powers offers comprehensive maintenance contracts across Karachi and beyond—contact us for pricing.