When a generator goes down, the first assumption may be that the problem is with the engine, controls, fuel system, or another familiar component.

But on today’s Tier 4 equipment, generator service companies and rental fleets increasingly need to understand another system: the emissions aftertreatment system.

In this episode of Powered to Win, Erik Duthie, Head of Operations at PowerChampions, sits down with Brittany Crowther, Vice President of Strategic Partnerships at Accurate OEM, to discuss generator emissions systems, why catalysts fail, and what service providers should understand before automatically replacing an expensive OEM component.

Emissions Systems Are Part of Generator Reliability

Brittany begins the conversation by explaining the role catalyst systems play in modern generator applications.

Depending on the engine and fuel type, an aftertreatment system may include components such as a diesel oxidation catalyst (DOC), diesel particulate filter (DPF), selective catalytic reduction (SCR) system, or other catalyst technology designed to reduce harmful exhaust emissions.

For generator owners and service providers, these systems are not simply add-ons. They are an important part of keeping applicable equipment operating properly and meeting emissions requirements.

When the aftertreatment system fails, the result can be an expensive repair—and potentially significant generator downtime.

Why Underloading Matters

One of the most useful parts of Erik and Brittany’s conversation centers on loading.

Brittany explains that underloading can significantly contribute to aftertreatment problems. When a generator operates below the conditions for which the engine and emissions system were designed, exhaust temperatures may not reach the levels necessary for the system to operate as intended.

Anyone who has spent time around diesel generators has probably encountered the consequences of extended light loading, including carbon buildup and wet stacking.

For rental fleets in particular, this can be difficult to control. A generator may be sized for a particular application and then spend extended periods operating at significantly less load than anticipated.

That makes proper sizing, operation, monitoring, and technician education increasingly important.

Cleaning Is Not the Same as Remanufacturing

Another key takeaway from the episode is the distinction between cleaning an emissions component and remanufacturing it.

A catalyst can sometimes become contaminated with soot and other buildup. Cleaning processes may remove some of that material, but Brittany explains that contamination is not always the entire problem.

The catalyst's active materials can also deteriorate or be damaged. In those situations, simply removing buildup may not restore the component to proper performance.

Accurate OEM’s remanufacturing process can go further. Depending on the component's condition, that may include cleaning, rebricking, recoating, and testing the finished unit against the appropriate application parameters.

The goal is not simply to make the component look clean. The goal is to restore function and verify performance.

Be Careful With Forced Regeneration

The discussion also touches on another issue technicians may encounter: regeneration.

When an emissions problem appears, forcing a regeneration may seem like an obvious troubleshooting step. But Brittany cautions that regeneration should not automatically become the answer to every aftertreatment problem.

Excessive heat or unnecessary forced regeneration can potentially damage internal catalyst components. That creates an important takeaway for generator service organizations: understand why the system is failing before deciding how to correct it.

That is where technician education becomes particularly important. The more informed technicians understand aftertreatment operation, engine loading, temperatures, regeneration, and catalyst construction, the better equipped they are to diagnose the actual problem instead of repeatedly treating the symptom.

The Cost of Downtime

For generator service companies and rental fleets, there is another major consideration: time.

Brittany explains that replacement OEM catalyst assemblies can be costly, particularly on large industrial equipment. Cost, however, is only part of the problem.

Availability can create an even bigger operational challenge.

If a replacement component has an extended lead time, the organization may have the budget to purchase it and still be left with a generator that cannot return to service quickly.

As Erik points out during the conversation, time is money in power generation.

According to Brittany, Accurate OEM’s remanufacturing program typically comes in at about half the cost of purchasing a new OEM catalyst, with a turnaround of approximately one to two weeks depending on the condition of the unit. She also notes that remanufactured units carry a one-year warranty.

For rental organizations managing multiple Tier 4 generators, having another option between cleaning and buying new can become an important part of controlling fleet maintenance costs and equipment availability.

Education May Be Just as Important as the Repair

One of the most PowerChampions-aligned themes of this episode comes near the end of the discussion.

Accurate OEM does not want service centers simply sending in failed catalysts over and over again. Brittany talks about helping customers understand why the failures occurred in the first place.

That matters.

At PowerChampions, we believe reliability starts with knowledgeable people. Whether technicians are diagnosing a generator controller, testing an automatic transfer switch, performing preventive maintenance, load banking a generator, or troubleshooting an emissions system, understanding why something happened is what helps prevent it from happening again.

The best technician is not simply someone who knows which component to replace.

It is someone who understands the system well enough to ask why it failed.

Another Tool for Generator Service Companies

Generator technology continues to evolve, and emissions aftertreatment has become another area where generator service companies need deeper expertise.

This episode of Powered to Win gives service managers, technicians, electrical contractors, and rental fleet operators a practical introduction to what these systems do, why they fail, and what repair options may exist.

It also reinforces a broader theme we return to often on Powered to Win: better information creates better decisions.

And in critical power, better decisions ultimately lead to greater reliability.

Watch or listen to Powered to Win with Erik Duthie and Brittany Crowther to learn more about Tier 4 generator emissions systems, catalyst remanufacturing, and how generator service organizations can better manage cost, compliance, and downtime.

Your Power. Our Mission.

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