Generator Maintenance Checklist

Facilities across many industries rely on generators for various reasons, from providing a backup during a power outage to providing power to auxiliary services. Whatever the generator’s purpose, regular maintenance ensures an extended lifespan, uninterrupted power supply, and good power quality. 

A regular generator maintenance checklist is a key piece of electrical preventive maintenance. This article offers comprehensive insights on developing a generator maintenance checklist so your organization won’t be left without power in a critical moment.

Introduction to Generator Systems

A generator is a device that converts mechanical energy into electricity. The generator’s engine pushes electrons through wires to provide electricity to outlets and devices. 

Types of Generators

There are several types of generators. The primary difference between each type is the fuel or energy source it uses to operate. These are some of the most common types of generators you can expect to encounter in an industrial or commercial facility.

• Diesel generator
• Gasoline generator
• Natural gas generator
• Propane gas generator
• Biogas generator
• Solar generator
• Wind turbine

Components of a Generator

Fuel-based units, such as natural gas or diesel generators, contain a fuel system complete with an engine. Wind turbines rely on rotor blades, and solar units utilize solar panels to run the generator. All generator types usually have these main components in common.

• Alternator
• Control panel
• Voltage regulator
• Battery

Pre-Maintenance Tips

When creating an electrical maintenance checklist, consider these preliminary steps to ensure generator maintenance tasks are conducted safely, efficiently, and effectively.

Regular Start-Up Exercise

Once per week, run the generator for a few minutes to ensure it’s in good working order. Listen for unusual sounds, and check for any odd smells coming from the unit and exhaust system while it’s running.

Review Manufacturer Guidelines

Take a look at the manufacturer’s recommendations and gather the tools, equipment, and materials needed to conduct generator maintenance.

Use Maintenance Schedule Templates

Review the generator maintenance checklist and ensure it includes all necessary tasks and inspection procedures. 

ServiceChannel offers a variety of maintenance templates as models for developing a generator maintenance checklist that fits your organization’s needs.

Shutdown and Isolate Generator

Before conducting generator maintenance, shut the generator down and isolate it from any power sources to prevent accidental startup and potential electrical hazards. Each type of generator will have lockout/tagout procedures, which should be included in the manufacturer’s guidelines.

The Comprehensive Generator Maintenance Checklist

Maintenance tasks are typically broken down into time intervals to ensure each generator maintenance checklist item is attended to at the proper time. These essential maintenance duties include how often the item should be performed.

Daily Inspection

Daily, perform a physical and visual inspection of generators to locate any obvious signs of damage and irregularities.

Check Fluid Levels

Verify all necessary fluids are sufficient and not overfilled. Fluid levels to check typically include engine oil, cooling system coolant concentration, and battery electrolyte levels. 

Identify Leaks or Damages

A generator inspection checklist should include examining the unit for any signs of leakage. Coolant or oil leaks can quickly cause damage to generators and should be promptly addressed.

Weekly Inspection

Conduct a more thorough visual inspection of generators once per week. Focus on components prone to stress and wear.

Fuel System Inspection

Regular inspections of a generator’s fuel line, fuel filter, and fuel tank help identify signs of contamination, blockages, and leaks. 

Battery Health Check

Inspect terminals and battery cables for corrosion, loose connections, and damage. Test the battery’s voltage to ensure it’s maintaining a proper charge. 

Monthly Inspection

A generator maintenance checklist should include monthly checks to ensure fluids are where they need to be and components aren’t showing any signs of giving out.

Oil Level Inspection

Check the level and condition of the engine oil. If the oil has grown darker and thicker, replace it. If the oil looks good, ensure the crankcase is full but not overfilled. Top off if necessary.

Coolant System Maintenance

Cooling systems are critical for ensuring generator motors don’t overheat. Monitor engine coolant levels and quality to help provide a long lifespan for the generator.

Inspect Alternator

The alternator is responsible for converting mechanical energy to electricity. Check for signs of deterioration and wear. If necessary, replace worn-out alternators or damaged alternator parts.

Filter Replacement

Inspect the air filter, fuel filter, and oil filter for each generator. Replace dirty or clogged filters to prevent contaminants from impacting generator performance. 

Annual Inspection

Industrial generators should undergo yearly inspections to assess their overall condition and undergo thorough maintenance tasks to keep them operating efficiently over the next year.

Cooling System Flush

Drain the old coolant from the generator each year and flush the system with clean water or a flushing agent. Refill with fresh coolant, and it should be ready for the next year of operation.

Wiring Inspection

Visually inspect wiring harnesses, connections, terminals, and all other electrical components once per year for indications of corrosion, damage, or deterioration.

Oil Change

Every year should begin with new oil. Drain the generator’s crankcase annually and refill it with fresh, clean oil.

Understanding Common Generator Problems

Issues might arise between maintenance intervals that require going through the facilities management checklist for generator maintenance. These are some common indicators that the generator needs attention.

Battery Failure

Insufficient maintenance, aging, and electrical system faults are common causes of battery malfunction.

Coolant Leaks

Worn gaskets, seals, or hoses can lead to coolant leaks, resulting in overheating and potential damage to the engine.

Low Fuel Levels

Keep an eye on fuel levels at all times. Operating a generator until it runs out of fuel can cause it to shut down unexpectedly and may cause wear on parts that impact its future performance and reliability. 

Failure to Start

Problems starting a generator can indicate one of many possible issues, most of which result from missed or deferred maintenance. When the unit won’t start, check the fuel, battery, and ignition systems. 

Clogged Lines

A fuel line obstruction prevents efficient fuel delivery to the generator’s motor. Clogged lines can result in intermittent stalling or stop the generator from starting at all.

Stalling During Operation

A stalled generator can indicate one or more issues. Clogged fuel lines, dirty filters, and loose connections are some common items to remember when the generator repeatedly stops running unexpectedly.

Tips for Long-Term Generator Care

Good generator care is a critical piece of effective preventive maintenance management. Follow these upkeep guidelines for a longer-lasting generator that delivers more reliable performance.

Regular Battery Monitoring

Monitor the battery charge rates regularly to avoid battery failure and ensure the generator starts when needed.

Follow a Maintenance Schedule

Develop and follow a schedule that sets tasks such as routine inspections, fuel system checks, fluid level monitoring, and filter replacements at appropriate time intervals.

Fuel Quality Management

Keep the generator filled with clean, quality fuel to prevent clogged lines, engine damage, and other potential issues with the generator motor.

Ensure Proper Location

Be sure to place generators at locations that comply with industry standards and regulatory agency requirements.

Don’t Forget About Professional Inspections!

If you don’t have the personnel to conduct more in-depth and comprehensive tasks, schedule regular inspections and maintenance with qualified technicians. Experienced professionals can identify and address potential issues before they escalate.

Unlocking Reliability with Preventive Maintenance Solutions

To summarize, developing a generator maintenance checklist and proactively addressing generator maintenance ensures a reliable power supply. Proper fluid levels, clean filters, and damage-free components are key to an efficient and effective piece of equipment.

A powerful facility management software solution like ServiceChannel is ideal for addressing all your facility maintenance needs, from scheduling routine HVAC maintenance to comprehensive electrical system maintenance tasks. Explore the ServiceChannel facility management platform today and move your operations into the future.