Major service - diesel generator (stationary and portable)
Estimated duration: 4 - 6 hours • Frequency: every 1,000 engine hours or annually
Equipment Details
| # | Service Action (1000-Hour / Annual Additional Items) | Type | Done | Notes |
|---|---|---|---|---|
| Cooling System | ||||
| 1 | Drain, flush and replace coolant | DRAIN/FILL | ☐ | |
| Engine | ||||
| 2 | Check/adjust injectors or send for testing | ADJUST | ☐ | |
| 3 | Check/adjust valve clearances | ADJUST | ☐ | |
| 4 | Inspect turbocharger for play and oil leaks | INSPECT | ☐ | |
| 5 | Inspect starter motor and solenoid | INSPECT | ☐ | |
| Air Intake | ||||
| 6 | Replace inner air filter element | REPLACE | ☐ | |
| Fuel System | ||||
| 7 | Drain and clean fuel tank | DRAIN | ☐ | |
| 8 | Replace fuel lines (if deteriorated) | REPLACE | ☐ | |
| Electrical | ||||
| 9 | Full electrical insulation resistance test (megger) | TEST | ☐ | |
| 10 | Inspect and service circuit breaker | INSPECT | ☐ | |
| 11 | Inspect and test all gauges, sensors and senders | INSPECT | ☐ | |
| Mechanical | ||||
| 12 | Full vibration analysis | TEST | ☐ | |
| Exhaust System | ||||
| 13 | Inspect exhaust silencer and rain cap | INSPECT | ☐ | |
| Compliance / Records | ||||
| 14 | Annual compliance check (if applicable) | CHECK | ☐ | |
| 15 | Update generator log book | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 8 - 20 L (depending on size) |
| Coolant | 50/50 ethylene glycol | 10 - 25 L (full system replacement) |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical diesel generators (stationary and portable). Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by generator size and configuration.
Parts / Consumables Required (1000-Hour / Annual Additional)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | All 500-hour parts (see 500-hr checklist) | - | ☐ | |
| 2 | Inner air filter element | 1 | ☐ | |
| 3 | Coolant (full system replacement) | 10-25 L | ☐ | |
| 4 | Fuel lines (if replacing) | As req. | ☐ | |
| 5 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager