A detailed Genset SEMI ANNUAL preventive maintenance Inspection checklist
1. Visual Inspection
2. Fluid Levels
3. Electrical System
4. Filters and Belts
- Shut down the generator and let it cool.
- Locate the oil filter and remove it carefully.
- Install the new oil filter, ensuring a tight seal.
- Check for leaks after starting the genset.
- Remove the air filter cover and take out the filter.
- Inspect for dirt, damage, or blockages.
- If clean, lightly tap to remove debris or use compressed air.
- Replace if excessively dirty or damaged.
- Locate the fuel filter and check for any visible damage.
- Remove the fuel filter using appropriate tools.
- Install a new fuel filter, ensuring proper orientation.
- Prime the fuel system and check for leaks.
- Examine belts for cracks, fraying, or glazing.
- Check the tension using a tension gauge or by pressing down.
- Adjust tension as needed using the tensioner or alignment.
- Replace worn belts to prevent operational failure.
- Shut down the generator and let it cool.
- Locate the oil filter and remove it carefully.
- Install the new oil filter, ensuring a tight seal.
- Check for leaks after starting the genset.
- Remove the air filter cover and take out the filter.
- Inspect for dirt, damage, or blockages.
- If clean, lightly tap to remove debris or use compressed air.
- Replace if excessively dirty or damaged.
- Locate the fuel filter and check for any visible damage.
- Remove the fuel filter using appropriate tools.
- Install a new fuel filter, ensuring proper orientation.
- Prime the fuel system and check for leaks.
- Examine belts for cracks, fraying, or glazing.
- Check the tension using a tension gauge or by pressing down.
- Adjust tension as needed using the tensioner or alignment.
- Replace worn belts to prevent operational failure.
- Shut down the generator and relieve pressure in the system.
- Locate the hydraulic filter and inspect it for damage.
- Remove and replace with a new hydraulic filter.
- Start the system and check for leaks.
- Locate the crankcase ventilation filter in the genset.
- Remove the filter and inspect for dirt and blockages.
- Clean using a suitable method or replace if necessary.
- Reinstall and ensure it is secured properly.
- Locate the coolant filter and check for leaks or damage.
- Remove the coolant filter carefully.
- Install a new coolant filter, ensuring proper alignment.
- Check coolant levels and top off if necessary.
- Check each filter for proper installation.
- Ensure all clamps and fittings are tightened.
- Look for any signs of leaks around filters.
- Document any discrepancies or issues found.
- Examine all hoses for cracks, bulges, or leaks.
- Check hose connections for tightness and integrity.
- Replace any damaged hoses immediately.
- Secure hoses to prevent movement during operation.
- Inspect each filter and belt area for fluid leaks.
- Use absorbent materials to identify the source of leaks.
- Address any leaks found by tightening connections or replacing components.
- Document any leaks in maintenance records.
- Inspect the alignment of the belts visually.
- Use a straight edge to check for proper alignment.
- Adjust using tensioners or reposition pulleys as needed.
- Recheck tension after adjustment to ensure stability.
- Record all observations and actions taken in the maintenance log.
- Include dates, part numbers, and any relevant notes.
- Ensure documentation is clear and accessible for future reference.
- Review the log regularly for compliance and tracking.
5. Cooling System
6. Starting and Stopping System
- Turn the ignition key to the 'start' position.
- Listen for the starter motor engaging.
- Observe the engine cranking process.
- Check for unusual sounds during operation.
- Ensure the motor stops when released.
- Engage the stop control to halt generator operation.
- Confirm the generator stops immediately.
- Test the emergency shut-off switch functionality.
- Ensure the stop control is accessible and clearly marked.
- Inspect for any signs of wear or damage.
- Locate the fuel shut-off valve.
- Manually operate the valve to ensure it opens and closes smoothly.
- Check for leaks around the valve.
- Verify that the valve is securely mounted.
- Inspect for any corrosion or damage.
- Inspect battery terminals for tightness.
- Look for corrosion or rust on connections.
- Clean terminals with a wire brush if necessary.
- Ensure cables are not frayed or damaged.
- Check for proper alignment of connections.
- Use a multimeter to check voltage levels.
- Inspect for any bulging or leaking battery cases.
- Confirm the battery is securely mounted.
- Check for signs of electrolyte leakage.
- Ensure battery age is within operational limits.
- Activate the ignition to engage glow plugs.
- Monitor the glow plug indicator light on the dashboard.
- Check for heating of the glow plugs via temperature.
- Inspect wiring for damage or corrosion.
- Test continuity of each glow plug.
- Examine all wiring harnesses for frays or breaks.
- Inspect connectors for corrosion or looseness.
- Ensure all connections are secure and clean.
- Look for signs of overheating or burn marks.
- Replace any damaged components as needed.
- Test the relay by applying voltage to its terminals.
- Listen for clicking sounds indicating activation.
- Check for overheating or physical damage.
- Inspect wiring connected to the relay for integrity.
- Replace the relay if it fails to operate.
- Power on the control panel and observe indicators.
- Verify that no warning lights are illuminated.
- Check the display for any error messages.
- Refer to the manual for troubleshooting codes.
- Document any issues found for further investigation.
- Connect a diagnostic tool to the ECM.
- Check for firmware updates or recalls.
- Verify settings align with manufacturer specifications.
- Inspect for visible signs of damage or wear.
- Document the programming status.
- Simulate a power outage to trigger ATS.
- Observe the switch functioning and engaging the genset.
- Check for any delays or malfunctions.
- Inspect connections for corrosion or wear.
- Verify the manual override function works.
- Engage the pre-lubrication system and listen for operation.
- Check oil pressure readings before starting the engine.
- Inspect the pre-heating system for proper operation.
- Look for leaks in hoses or connections.
- Ensure all components are functioning as intended.
- Listen for grinding, knocking, or excessive vibration.
- Record any abnormal sounds for analysis.
- Inspect engine mounts and components for looseness.
- Check for proper alignment of the starter motor.
- Consult with a technician if issues are detected.
Use in Manifestly