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

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

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