Intermediate service - diesel generator (stationary and portable)
Estimated duration: 2 - 3 hours • Frequency: every 500 engine hours
Equipment Details
| # | Service Action (500-Hour Additional Items) | Type | Done | Notes |
|---|---|---|---|---|
| Fuel System | ||||
| 1 | Replace fuel filter element | REPLACE | ☐ | |
| 2 | Check fuel tank for water and sediment | CHECK | ☐ | |
| Air Intake | ||||
| 3 | Replace outer air filter element | REPLACE | ☐ | |
| 4 | Clean and inspect air intake and exhaust louvres | CLEAN | ☐ | |
| Cooling System | ||||
| 5 | Test coolant concentration with refractometer | TEST | ☐ | |
| Drive / Belts | ||||
| 6 | Replace fan belt (or inspect and retension) | REPLACE | ☐ | |
| Alternator / Voltage Regulation | ||||
| 7 | Check alternator brushes and slip rings | CHECK | ☐ | |
| 8 | Inspect voltage regulator | INSPECT | ☐ | |
| Electrical / Protection | ||||
| 9 | Test automatic transfer switch (ATS) operation | TEST | ☐ | |
| 10 | Test battery under load (CCA) | TEST | ☐ | |
| 11 | Inspect wiring and connections for heat damage | INSPECT | ☐ | |
| 12 | Test all protection relays (over-current, under-voltage, over-speed) | TEST | ☐ | |
| Oil Analysis | ||||
| 13 | Take engine oil sample for analysis | 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 (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 (500-Hour Additional)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | All 250-hour parts (see 250-hr checklist) | - | ☐ | |
| 2 | Fuel filter element | 1 | ☐ | |
| 3 | Outer air filter element | 1 | ☐ | |
| 4 | Fan belt (if replacing) | 1 | ☐ | |
| 5 | Oil sample bottle | 1 | ☐ | |
| 6 | Coolant test strips | 1 pack | ☐ | |
| 7 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager