Replacing Parts of Commercial Generators

A commercial or industrial generator is an expensive investment for many businesses. As the unit is often used in unexpected or unpredictable situations, it is fundamental to ensure the system is always operating at peak capacity. The cost of replacing a unit ensures many generator owners will replace individual parts, rather than purchasing an entirely new unit.

While these devices are intended to be a long-lasting contribution to a business, some breakdowns are inevitable. Regular and routine servicing is the easiest way to identify these issues before it causes any significant damage. Adopting a proactive approach will also maximise the unit’s reliability, ensuring it performs to the required standard when needed. The following is a collation of the most common parts that require replacement on a commercial or industrial generator.

Oil Filter

Oil filters are fundamental to the delivery of clean oil supplies to different parts of the engine, to maintain smooth running, and reduce the level of wear and tear. As the oil filter continuously pumps liquid through the filter, residue and particles can build up over time. These blockages limit the ability of the screen to “clean” the oil in future cycles. If the oil is dirty, it will become thick and abrasive, causing damage to the system interior. The recommended frequency of replacing an oil filter depends on the type of generator and level of use. Oil filter replacements are generally calculated based on the specific hours of operation.

Fuel Filter

Fuel filters prevent dust and other foreign particles from entering into the engine. Without fuel filters, these impurities will potentially damage the generator and hinder the unit’s performance. Every generator requires a different type of fuel filter, designed to suit the specific model. Genuine and reliable parts must be used in replacement to ensure the maximum life expectancy of your unit. The recommended regularity of fuel filter replacements depends on the level of usage. The general rule is that filters must be replaced after around 500 hours of operation, which equates to approximately 20 consecutive days of continuous use.


The coolant system within a generator ensures the system can adequately cool after use and helps minimise corrosion. The replacement of coolant and clearing of the cooling system is required every 2,000 hours or 2-years, whichever comes first. While some coolants are compatible with others, changing the chemical balance in the cooling system can affect the unit’s overall performance, which is why mixing different types of coolant is not recommended.


A belt is a flexible material used to link two or more rotating shifts within a generator. These are used as a source of motion, to transmit power efficiently and track movement. A belt inspection is required to determine when the device needs replacement, and any works should comply with the relevant engine and belt manufacturing guidelines. Failure to identify any breaks or cracks immediately can result in irreversible damage to the generator or require costly repairs.


The role of a generator hose is to carry vital liquids throughout the unit. This transportation may include coolant, lubricating oil, fuel and exhaust gases. These hoses are typically made of resistant materials, but may still crack or break over time. A tube will require replacement when it begins to become thin and brittle, shows signs of crack or has evident cracks. These checks are typically conducted during routine maintenance or service. The regularity of replacements varies greatly, with some lasting up to 25 years and others requiring replacement every 5 years.

Air Filter

A properly maintained air filter will prevent dust and other particles from entering the engine. If dust does enter the carburetor, it can cause unwanted engine wear, as well as issues with starting and running the unit. Maintenance instructions vary by model, so the specific make of your generator will influence how often the air filter must be replaced.

Start and Control Batteries

Batteries are an integral element of a generator. The primary role of a generator battery is to provide power to the generator engine when a power outage occurs. Many generator owners report a failed battery as the most common reason for a generator failure. By maintaining and monitoring a battery, a generator owner can track the performance of the device. This process includes logging the purchase date to follow the expected lifespan, checking the specific gravity of electrolyte for each cell and adding the appropriate mixture of electrolyte and water. When a battery is due for replacement or any unaddressable issues are identified, Reactive Generators can swap your generator battery with an authentic, good-quality and long-lasting alternative.

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