Minor service - diesel generator (stationary and portable)
Estimated duration: 1 - 2 hours • Frequency: every 250 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine | ||||
| 1 | Drain and replace engine oil (15W-40 CI-4/CK-4) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| 3 | Inspect air filter element - replace if dirty | INSPECT | ☐ | |
| 4 | Drain fuel/water separator and check for contamination | DRAIN | ☐ | |
| 5 | Check coolant level and concentration | CHECK | ☐ | |
| 6 | Inspect radiator and hoses for leaks, damage or swelling | INSPECT | ☐ | |
| 7 | Inspect fan belt tension and condition | INSPECT | ☐ | |
| Exhaust System | ||||
| 8 | Check exhaust for smoke and leaks | CHECK | ☐ | |
| 9 | Inspect exhaust flex couplings | INSPECT | ☐ | |
| Electrical | ||||
| 10 | Check battery terminals, voltage and electrolyte level | CHECK | ☐ | |
| 11 | Check control panel operation and alarms | CHECK | ☐ | |
| 12 | Test emergency stop | TEST | ☐ | |
| 13 | Check earth connections | CHECK | ☐ | |
| Load Testing | ||||
| 14 | Run load bank test (25% / 50% / 75% / 100% rated load) | TEST | ☐ | |
| Mechanical | ||||
| 15 | Check vibration isolation mounts | CHECK | ☐ | |
| 16 | Inspect fuel lines and connections | INSPECT | ☐ | |
| Enclosure / Canopy | ||||
| 17 | Inspect enclosure/canopy (vents, louvres, latches) | INSPECT | ☐ | |
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 (system) |
| 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
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 8-20 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Air filter element - if replacing | 1 | ☐ | |
| 4 | Fuel/water separator element | 1 | ☐ | |
| 5 | EP2 grease | As req. | ☐ | |
| 6 | Coolant (pre-mixed or concentrate) | As req. | ☐ | |
| 7 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager