Free generator 250-hour service procedure

• The MapTrack generator 250-hour service procedure contains 17 checks across 6 sections. Sections covered: Engine, Exhaust System, Electrical, Load Testing, Mechanical, Enclosure / Canopy.
• Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant level and concentration, inspect radiator and hoses, inspect fan belt tension and condition.
• Exhaust system: check exhaust for smoke and leaks, inspect exhaust flex couplings.
• Electrical: check battery terminals, voltage and electrolyte, check control panel operation and alarms, test emergency stop, check earth connections.

Learn more about maintenance and work orders in MapTrack.

• Reliable power when needed: regular oil, filter and coolant maintenance ensures the generator starts and runs at full capacity during power outages or peak demand.
• Prevents wet stacking: load bank testing at each service burns off carbon and fuel residue that accumulates when generators run at light load.
• Extended component life: clean oil and correct coolant concentration reduce wear on engine, alternator and cooling system components.
• Lower repair costs: a 250-hour service costs a fraction of an emergency breakdown repair. Catching issues early prevents cascading damage.
• Compliance: documented service records demonstrate that generators are maintained to Australian Standards and WHS requirements, supporting insurance and regulatory obligations.
• Resale value: a complete service history with documented 250, 500 and 1,000-hour services increases the generator's value at resale.

• Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant level and concentration, inspect radiator and hoses, inspect fan belt tension and condition.
• Exhaust system: check exhaust for smoke and leaks, inspect exhaust flex couplings.
• Electrical: check battery terminals, voltage and electrolyte, check control panel operation and alarms, test emergency stop, check earth connections.
• Load testing: run load bank test at 25%, 50%, 75% and 100% rated load.
• Mechanical: check vibration isolation mounts, inspect fuel lines and connections.
• Enclosure / canopy: inspect vents, louvres and latches.

1. Shut down the generator and allow the engine to cool. Isolate the generator from the electrical supply. Ensure the area is well ventilated.

   Switch the generator to off mode and open the main circuit breaker. Isolate from the electrical supply using the designated isolation point. Allow at least 15 minutes for the engine to cool. Ensure the service area has adequate ventilation for exhaust fumes during load testing.

2. Record the equipment details and current hour meter reading at the top of the service procedure form.

   Capture the generator serial number, fleet ID, make, model, rated output (kVA/kW), fuel type, site location and controller type. Cross-check the hour meter reading against the last service to confirm the 250-hour interval.

3. Start with the engine section: drain the old engine oil, replace the oil filter, fill with new oil to the correct level, then inspect the air filter, drain the fuel/water separator and check coolant level and concentration.

   Use 15W-40 CI-4 or CK-4 engine oil as specified by the manufacturer, typically 8 to 20 litres depending on generator size. Pre-fill the new oil filter before fitting. Inspect the air filter for damage and clean with compressed air if reusable. Drain the fuel/water separator and check coolant concentration with a refractometer.

4. Inspect the radiator and hoses for leaks or damage. Check fan belt tension and condition.

   Inspect the radiator core for blocked fins, corrosion or impact damage. Check all hoses for swelling, cracking or softness, paying attention to the upper and lower radiator hoses and heater hoses. Measure fan belt deflection against the manufacturer specification, typically 10 to 15 mm at the midpoint.

5. Check battery terminals, voltage and electrolyte level. Check the control panel operation, alarms and earth connections. Test the emergency stop.

   Battery voltage should read 12.4V or above for a fully charged battery. Clean terminals with a wire brush if corroded. Check the control panel for correct operation of all indicators and alarms. Verify the earth connection is secure and corrosion-free. Test the emergency stop from all accessible locations.

6. Start the generator and run the load bank test at 25%, 50%, 75% and 100% rated load. Record voltage, frequency and temperature readings at each step.

   Connect the load bank and apply load in steps, holding each level for at least 5 minutes. Record output voltage (should be within 2% of rated), frequency (should be 50 Hz plus or minus 0.5 Hz) and coolant temperature at each load step. The 100% load step confirms the generator can deliver its full rated output.

7. While running, check the exhaust for smoke and leaks. Inspect exhaust flex couplings. Check vibration isolation mounts.

   Black smoke indicates overloading or poor combustion. Blue smoke indicates oil burning. White smoke on startup is normal in cool conditions but should clear within minutes. Inspect exhaust flex couplings for cracks or leaks. Check vibration mounts for cracking, sagging or detachment.

8. Inspect fuel lines and connections. Inspect the enclosure or canopy, including vents, louvres and latches.

   Check all fuel lines for chafing, cracking or weeping connections. Inspect the enclosure for damage, ensure all vents and louvres are clear of obstruction and open freely, and verify all latches and locks are functional.

9. Record any defects or recommendations in the notes section. Set the next service due hours (next 250-hour and next 500-hour intervals). Sign off and update the generator's maintenance log.

   Classify defects as critical, major or minor. Calculate the next 250-hour and 500-hour service points from the current meter reading. Update the generator service sticker and fleet management system. Capture the technician name, qualification and date.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• AS/NZS 3010 (Generating Sets)
• AS 2790 (Transportable Generating Sets)
• WHS Act 2011
• WHS Regulations 2011

• Model WHS Regulations (Safe Work Australia)
• Model Work Health and Safety Act (Safe Work Australia)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

• Generator 500-hour service procedure
• Generator 1000-hour / annual service procedure
• Generator inspection checklist
• Maintenance management (MapTrack)
• Construction industry
• Plant compliance
• MapTrack pricing