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Diesel Generator Maintenance Guide: A, B, C & D Check Procedures

Introduction:

Regular maintenance is essential to keep diesel generators running efficiently and reliably. A well structured maintenance checklist ensures optimal performance, prevents unexpected failures, and extends the lifespan of the equipment. This checklist covers daily, periodic, and annual maintenance tasks, including oil changes, cooling system checks, fuel system inspections, and battery maintenance. By following these guidelines, facility managers and operators can ensure uninterrupted power supply and reduced downtime for critical operations.

Diesel Generator Maintenance Checklist


A-CHECK (DAILY MAINTENANCE)

  1. Cleaning - Clean engine and premises.

  2. Checking Engine Oil Level - Ensure oil is between H and L marks on the dipstick, top up if required.

  3. Checking Coolant System - Verify coolant level in radiator, top up with premix coolant if needed. Inspect belt condition.

  4. Checking Fuel System - Inspect fuel strainer, clean breather on fuel tank, drain sediments/water from fuel water separator, and refill fuel tank at end of the day.

  5. Checking Air System - Monitor vacuum indicator for air restriction (red band). Inspect air filter sealing and condition.

  6. Other Checks

    • Check for leaks and rectify if needed.

    • Run engine and record all parameters.

  7. Checking Battery System

    • Voltage should be above 26V.

    • Ensure battery terminal tightness (use an insulated spanner).

    • Check specific gravity using a hydrometer (1.21-1.24 or 1220-1250).

B-CHECK (EVERY 225-250 HRS. OR 6 MONTHS, WHICHEVER IS EARLIER)

  1. Changing Lubrication Oil - Warm up and stop engine, drain oil, refill with new oil to H mark on dipstick.

  2. Changing Lube Oil Filter - Clean filter head, replace filter, and ensure a proper seal with lubricating oil.

  3. Checking Cooling System - Repeat A checks, inspect fan hub & drive arrangement, and radiator cap seal.

  4. Changing Fuel Filter & Water Separator - Replace filters, apply light oil film for proper sealing, drain sediments from fuel tank.

  5. Checking Air Filter/System - Clean air filter using dry air at max pressure 0.5 kg/cm².

  6. Other Checks - Repeat A checks, check battery electrolyte level & specific gravity, secure all engine electrical connectors.

C-CHECK (EVERY 475-500 HRS. OR 12 MONTHS, WHICHEVER IS EARLIER)

  1. Checking Lubrication System - Repeat A & B checks, clean breather.

  2. Checking Cooling System - Inspect coolant condition, recovery bottle, radiator seals, and clean radiator externally using pressurized air.

  3. Checking Fuel System - Inspect fuel line joints, tighten connections, and clean feed pump & baby filter.

  4. Checking Air Filter/System - Repeat A & B checks.

  5. Other Checks - Repeat A & B checks, inspect and replace AVMs (Anti Vibration Mounts) if required.

D-CHECK (EVERY 950-1000 HRS. OR 24 MONTHS, WHICHEVER IS EARLIER)

  1. Checking Lubrication System - Repeat A, B & C checks, clean breather, and inspect Blow Bye.

  2. Checking Cooling System - Inspect and replace belt, belt tension, and tensioner. Replace coolant and radiator cap.

  3. Checking Fuel System - Clean fuel tank and inspect fuel hoses. Replace damaged fuel hoses if necessary.

  4. Checking Air Filter/System - Repeat A, B & C checks. Inspect turbocharger end clearances.

  5. Other Checks - Repeat A, B & C checks, tighten all clamps, and check valve clearances.

    • Intake Clearance: 0.254mm

    • Exhaust Clearance: 0.508mm

Final Words:
Diesel generator maintenance is not just about routine inspections; it is a proactive approach to prevent failures and maximize efficiency. By adhering to this comprehensive A to D maintenance checklist, facility managers can reduce costly breakdowns and ensure continuous power availability. Regular servicing, timely replacement of parts, and thorough system checks are crucial for safety, compliance, and long term performance. Implementing a disciplined maintenance routine will keep your generator in peak condition, ready to deliver power whenever needed.

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