Top Tips For Simplifying Your Generator Maintenance Checklist

The leading reason companies invest in prime diesel generator sets is to obtain uninterrupted, affordable power supply to remote locations with little to no national grid connection or as an alternative power source during grid failure.

“Having an uninterruptible power supply will ensure that in an emergency situation, your commercial building or facility is fully prepared to maintain critical power. Being proactive and carrying out sufficient testing, monitoring and maintenance of your fuel system will allow facility managers to identify problems and make improvements”. – Vital Power

Why Having a Generator Maintenance Checklist Is Important

Avoid Power Outages

Without regular diesel generator maintenance, insignificant problems can escalate into much bigger problems. Catching repairs as early as possible using a generator checklist avoids running the risk of power outages, electrical hazards and your valuable asset not reaching its full lifecycle potential.

Efficiency

Regular maintenance and testing of components’ condition mean that any issues found that prevent your Genset from producing at optimum level can be resolved quickly. 

Reduce Operating Costs

Replacing and repairing generator components costs valuable time, money and resources. Careful maintenance of your valuable asset and preparing for the unexpected prevents any unexpected repairs.

Prevent Carbon Monoxide Poisoning

It is critical to locate your generator in a well-ventilated position to release toxic fumes into the open air so that the exhaust system is operating safely. A generator that isn’t well-maintained produces harmful carbon monoxide when inhaled, putting your workforce at risk.

It’s also important to change out the air filter at regular intervals. When you run the generator toxic particulate matter is caught by the air filter, but if the filter is oversaturated or worn out, it will stop being effective, possibly leading to the build up or emenation of toxic fumes.

Whether you’re operating an industrial generator ir backup generator, changing the air filter is always important.

Reliability

Prioritise which parts and when to check them, helping keep your asset running at peak performance for its entire lifespan. 

How Often Should I Check The Generator?

When thinking about creating your maintenance plan, it should include daily checks and hourly scheduled services.

Daily Preventative Maintenance Checks

The most common causes of generator failure can be detected with a simple visual inspection. Inspections involve checking fluid levels, testing batteries, cleaning, analysing general wear and tear and verifying the accuracy of the control panel readings. They will undertake a gravity and load test to verify the generator’s electrical and mechanical operations are working properly.

Check the fuel – Low fuel levels lead to long-term damage to the internal components and even a power outage. You wouldn’t leave your house without making sure you have enough fuel for your journey – the same applies to a generator.

Assess asset data – In many remote locations, establishing a reliable broadband connection can be expensive, however, it is vital to assess data about asset performance daily and at regular intervals to ensure the generator operates effectively.

Check oil levels – Lack of oil causes overheating, over crank, cracked heads and broken pistons and eventual engine failure. Keeping oil levels topped up regularly using the same quality and brand of oil as the manufacturer’s recommendations allows the generator to continue optimal energy production.

Hourly Scheduled Services

“Preventive maintenance for diesel engine generators plays a critical role in maximizing reliability, minimizing repairs and reducing long term costs. By following generally recognized diesel maintenance procedures and specific manufacturer recommendations for your application, you’ll be assured that your standby power system will start and run when you need it most.” – Cummins Power Generation

Each diesel generator is unique. When creating your bespoke scheduled service plan, it is imperative to follow the manufacturer’s specifications for your Genset’s operating conditions, use a qualified technician, consider the environment in which it’s located and your resources for specific power application.

“Different manufacturers specify different maintenance schedules for the generators they produce. A home standby generator that only supplies backup power during an outage has an oil-change service interval of 200 hours. Compare that to a car. 200 hours at 60 MPH is 12,000 miles. A 2018 Toyota Camry requires an oil change every 9000–10,000 miles.” – Starlight Generator

Below illustrates recommended hourly scheduled services:

Automate Your Generator Preventative Maintenance Plan

How is your team currently keeping records? Could you easily reference your maintenance history to see when a 250 hour service was completed?

Delayed audit reports and missing asset data are some of the many dilemmas inspectors face when relying on paper-based inspection methods. Locating maintenance paper logs, re-writing checklists and losing historical information on your generator leads to double the work. 

A computerized maintenance management system (CMMS) company such as 60Hertz, mimics traditional maintenance checklists and procedures to replace your entire paper trail from a single platform. Inspectors can document checks carried out, take photographic evidence, automatically store and archive vital asset data and prepare for audits in a Fully DFARS Compliant cyber secure application. Supervisors can schedule customized generator maintenance checks, set reminders for upcoming tasks and locate information at the click of a button.