How-to · 3 min read · Updated 6 November 2026
Moving a standby generator: weights, fuel and reconnection
How heavy are generators?
Generator weight rises quickly with output and enclosure type. The figures below are rough guides for diesel sets; acoustic enclosures and integrated fuel tanks add a lot of weight. Use the manufacturer's data sheet for the actual figure.
| Generator size | Typical weight range |
|---|---|
| 10 to 20 kVA, open frame | 300 to 700 kg |
| 20 to 60 kVA, acoustic canopy | 700 kg to 1.5 tonnes |
| 100 to 200 kVA, acoustic canopy | 1.5 to 3.5 tonnes |
| 500 kVA and above | 5 tonnes and upwards |
| Bunded base fuel tank, when full | Add the fuel weight, around 0.85 kg per litre of diesel |
A 1,000 litre base tank full of diesel adds roughly 850 kg. That can change both the total weight and the centre of gravity, which matters for lifting.
Before the move
- Get the generator and any automatic transfer switch isolated and disconnected by a competent electrician
- Run the fuel down or drain it to the level agreed with the mover and the transport plan
- Disconnect and secure batteries, and protect terminals from short circuits
- Check for oil, coolant or fuel leaks, and fix them or contain them before transport
- Find the lifting points and the lifting instructions in the manual
- Photograph all connections and labels to make reconnection easier
Fuel carried in the tanks of machinery has its own rules under the dangerous goods regime, and limits apply. Agree with your mover how much fuel can stay in the tank for the journey rather than guessing.
Lifting and transport
Most canopied generators have marked lifting eyes on the roof or forklift pockets in the base. Lift only from these, and only with lifting gear rated for the total weight including fuel. Lifting from the canopy panels or exhaust can tear them away.
- Forklift with long enough tines for the base pockets, for short moves and loading
- HIAB lorry for loading and placing near the vehicle
- Mobile crane for rooftops, compounds behind walls or very heavy sets
- Flatbed or low-loader secured with rated chains or straps for road transport
Preparing the new location
- A level concrete base or plinth able to carry the full weight, sized for the footprint
- Clearance around the set for maintenance access and cooling airflow
- An exhaust route that keeps fumes away from doors, windows and air intakes
- Bunding or a bunded tank to contain fuel leaks, especially near drains
- Protection from vehicles where the set sits in a yard or car park
- Agreement with neighbours or the landlord about noise and position
If the generator is outdoors and holds oil above certain quantities, the oil storage rules may apply, which in England generally cover containers of 201 litres or more at non-domestic premises. Check with your fuel supplier or environmental adviser if you are unsure.
Recommissioning and testing
Once positioned and reconnected, the set should be checked by a generator engineer before it is relied on. Typical checks include fluid levels, battery condition, control panel settings, a start test, a load test using a load bank or the building load, and a test of the automatic changeover if there is one.
Do not skip the load test. A generator that starts on the day it is moved but fails under load during a power cut is a costly surprise, especially for data rooms, care homes and cold stores.
Typical costs
| Job | Typical guide price (2026) |
|---|---|
| Small open-frame set moved within a site | £300 to £900 |
| Canopied set relocated locally by HIAB | £800 to £2,500 |
| Large set lifted by mobile crane | £2,000 to £6,000 or more |
| Engineer recommissioning and load test | Often a few hundred pounds upwards |
Electrical disconnection, reconnection and any new base or bunding are usually separate costs. Ask the mover for a lift-and-place price and get the electrical and engineering work quoted alongside it so you can see the full figure.
Common mistakes
- Underestimating weight by forgetting the fuel in the base tank
- Lifting from the wrong points or without a spreader beam where one is specified
- Placing the set where exhaust fumes enter the building
- Leaving the site without standby power and no temporary hire set arranged
- Not booking the electrician and engineer for the same day as the move
Frequently asked questions
Do I need to drain the fuel before moving a generator?
Not always, but the fuel level needs to be agreed before the move. Fuel adds a lot of weight, it can shift the centre of gravity and limits apply to fuel carried in machinery tanks on the road. Many movers ask for tanks to be run down or reduced to a low level. Ask your mover and generator engineer what is right for your set and journey.
Can a generator be moved without a crane?
Yes, in many cases. Smaller sets can be moved on skates, pallet trucks or forklifts, and HIAB lorries handle a wide range of mid-sized canopied sets. A mobile crane is usually needed for rooftops, positions behind buildings or walls, and the heaviest sets. The mover will choose the method after checking the weight, lifting points and access.
How do I keep power on while my generator is being moved?
If you need continuous standby cover, hire a temporary generator for the move period and have it connected before the main set is disconnected. This is common for data rooms, healthcare sites and cold storage. Plan the changeover with your electrician so the temporary set is tested before the permanent one is taken away.
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