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Diesel generator maintenance checklist

Diesel generator maintenance checklist

This maintenance checklist helps you stay on top of routine checks, from safety alarm tests to load testing, leading to consistent performance.

Use this template
or download pdf
Diesel generator maintenance checklist

This maintenance checklist helps you stay on top of routine checks, from safety alarm tests to load testing, leading to consistent performance.

Use this template
or download pdf

About the Diesel generator maintenance checklist

In industries where reliable power is a must, maintaining your diesel generator is key to avoiding costly downtime. A diesel generator maintenance checklist gives you a systematic way to monitor everything from safety alarms to load testing so that your generator can perform at its best. Whether you work in manufacturing, construction, or any other industry, this checklist is designed to simplify routine checks and make your equipment last longer.

Purpose and benefits of the diesel generator maintenance checklist

This checklist is structured to guide you through each step of the inspection process, from initial assessments to performance testing. With sections for recording key measurements like crankshaft deflection and compression pressures, it ensures no detail is overlooked. Each part of the generator, including safety alarms and voltage regulation, is covered to provide a comprehensive maintenance routine.

Because of its clear, step-by-step format, the checklist helps your team conduct thorough inspections while minimizing errors. Since you can also add photos and detailed notes directly into the checklist, you streamline documentation, and it’s easier to track trends over time.

How to use the diesel generator maintenance checklist

Maintaining a diesel generator requires careful attention to detail and consistency, and this checklist aids you in achieving that. Here’s a quick guide to using it:

  1. Start by reviewing equipment details: Enter the generator’s description and upload photos to document its current condition. This creates a baseline for future inspections.
  2. Conduct and record key measurements: Use the template to capture essential data such as compression pressures, bearing temperatures, and crankshaft deflection. These metrics are vital for tracking wear and tear.
  3. Test safety alarms and automatic functions: Follow the checklist to confirm that alarms and emergency functions, like the overspeed stop and automatic start, are working as intended. This allows you to identify potential safety issues before they escalate.
  4. Perform load and governor tests: Test the generator under different load levels and check the governor’s response. Make sure to document fuel consumption at 100% load to monitor efficiency.
  5. Analyze data and track progress: You can review the collected data over time using the app’s data analysis feature and identify trends in the generator’s performance. Use the insights to schedule preventive maintenance or address any recurring issues before they become critical.

Download Lumiform’s diesel generator maintenance checklist today

With this diesel generator maintenance checklist, you can keep every inspection on track. This template makes it convenient to record vital measurements, safety tests, and performance data in one place. Track everything from load tests to alarm functions so that your generator performs reliably.

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Preview of the template
Audit
Resume of Inspection
Inspections
Overall assessment
Inspector
Equipment Details
Equipment description
Equipment
Documentation
Shop test program approved by GL
Generator shop test by manufacturer
Measurements
Ambient air temperature and pressure
Maximum compression pressures were taken?
Maximum combustion pressures were taken?
Bearings Temperatures were taken?
Crankshaft deflection was measured?
Starting Test at No Load
Starting test was performed?
Safety devices and Alarms
L.O. low pressure alarm is working properly?
C.W. high temperature alarm is working properly?
Lube oil engine alarm is working?
Water level low alarm is working?
Low voltage alarm is working?
Three automatic start failure is working?
Overspeed stop is working properly?
Automatic start function is working?
Automatic stop function is working?
Emergency stop function is working?
Load Test
Test at 0% MCR load
Test at 25% MCR load
Test at 50% MCR load
Test at 75% MCR load
Test at 100% MCR load
Test at 110% MCR load
Governor Test
Governor response is acceptable?
Fuel Oil Consumption taken at 100%MCR
SFOC
Torsional Vibration Measurements
Torsional vibration is acceptable?
Voltage Regulation Test
Voltage regulation is acceptable?
Overhauling of Set
Comments on overhauling of generator set
Conclusion
Final comments on inspection
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Frequently asked questions

What maintenance is required on a diesel generator?

Routine maintenance for a diesel generator includes checking and changing the oil, inspecting fuel and air filters, testing the battery, and ensuring all connections are secure. Regular inspections of belts, hoses, and coolant levels are also essential. Performing load tests and checking fuel quality will keep the generator running efficiently and prevent major issues down the line.

What are common signs that a diesel generator needs maintenance?

A few signs to watch for include difficulty starting, excessive smoke, unusual noises, and a sudden drop in performance. If you notice inconsistent voltage output or your generator is overheating, it’s time to schedule a maintenance check. Leaks, particularly from fuel or oil, are another sign of potential trouble.

How often should I perform diesel generator maintenance checks?

Maintenance checks should be performed at least every 250 hours of use or every six months, whichever comes first. It also depends on your generator’s usage, with more frequent checks required for units that run continuously or in critical applications.

How do I properly store my diesel generator when it’s not in use?

Before storing your diesel generator, clean it thoroughly, change the oil, and fill the tank with fresh fuel to prevent condensation. Store it in a cool, dry area, preferably indoors, and cover it to protect it from dust and debris. Consider adding a fuel stabilizer to extend fuel life, and run the generator briefly every few months to keep its components lubricated.

Why is load testing important for diesel generators?

Load testing verifies that your diesel generator can handle its full operational capacity. It helps identify weaknesses, such as voltage fluctuations or poor fuel efficiency, under real-world conditions. Regular load testing also prevents “wet stacking,” where unburnt fuel accumulates in the exhaust, which can reduce the generator’s performance over time.

This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.