Free generator maintenance checklist
Free generator maintenance checklist (PDF-ready). Covers diesel and portable generators: fuel, oil, coolant, electrical and load testing. Download free.
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Updated 26 Oct 2026
Generator Maintenance Checklist
Inspection, servicing and load test log | Diesel Petrol Standby generators
A - Visual Inspection
B - Fluid Checks
C - Electrical Checks
D - Operational Test (Run Under Load)
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Short answer
A generator maintenance checklist records the periodic service of a diesel or portable generator: condition, fuel, oil and coolant, filters, battery and charger, transfer switch, breakers and an operating test under load. Technicians follow the manufacturer's hour and calendar intervals. Regulation 213 of the model WHS Regulations requires competent-person maintenance following the manufacturer; AS/NZS 3010:2017 covers generating set electrical installations.
Checked against Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack generator maintenance checklist contains 39 checks across 4 sections. Sections covered: A - Visual Inspection, B - Fluid Checks, C - Electrical Checks, D - Operational Test (Run Under Load).
- Log the hour meter at every service; oil and filter changes follow the manufacturer's hour or calendar interval, whichever comes first.
- Where NFPA 110 applies, clause 8.4.2 requires generators to be exercised at least monthly for at least 30 minutes.
- Diesel sets that cannot meet NFPA 110's monthly loading need an annual supplemental load test at 50 then 75 percent (clause 8.4.2.4).
- Use AS/NZS 3010:2017 for electrical installation requirements. Set service and load test schedules from the manufacturer's instructions and any other rules that apply.
- In Victoria, the OHS Regulations 2017 Part 3.5 apply instead of the model WHS Regulations.
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Used by construction, mining and field service teams
What is a generator maintenance checklist?
A generator maintenance checklist is a structured inspection and service form used to verify a generator's mechanical, electrical and safety condition. Unlike a simple pre-start check, a maintenance checklist covers both current condition and upcoming preventive maintenance tasks such as oil changes, filter replacements and load testing. Regular maintenance is critical for generators because they are often relied upon in emergencies or for continuous power on remote sites. A failed generator due to missed maintenance can halt an entire operation. The checklist follows the manufacturer service requirements; AS/NZS 3010 sets the installation requirements for generating sets.
Generators are classified as electrical plant under Australian WHS legislation, and their maintenance is governed by multiple regulatory frameworks. AS/NZS 3010:2017 covers the installation of generating sets (location, protection, earthing and bonding, changeover devices and generating sets supplying safety and essential services); it has no maintenance or load-test section, so service intervals and load testing follow the manufacturer recommendations under regulation 213 of the WHS Regulations. For transportable generators commonly used on construction sites, AS/NZS 3010:2017 replaced AS 2790-1989: its Appendix D covers the fuel, exhaust and electrical safety of transportable sets and Appendix B covers RCD-protected and other portable set configurations. Skipping scheduled generator maintenance creates a cascade of risks: fuel contamination from water ingress leads to injector damage, unmaintained coolant degrades and causes overheating, and corroded battery terminals prevent starting precisely when backup power is needed most. On remote mine sites and hospital facilities where generators provide essential or life-safety power, a maintenance failure can have consequences ranging from production losses to patient safety incidents.
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Let a tracker's estimated run hours keep the hour meter current and drive the next service: GPS tracker for generators.
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Benefits of using this generator maintenance checklist
- Reliable power when it matters most: regular maintenance prevents failures during critical operations or emergencies.
- Extended generator life: oil, coolant and filter changes at the correct intervals protect the engine.
- Electrical safety record: documented inspections of earthing, cabling and protective devices give a baseline when the installation is checked against AS/NZS 3010.
- Early fault detection: identifying fuel contamination, coolant leaks or battery issues before they cause failure.
- Cost savings: preventive maintenance is substantially cheaper than emergency repair or generator replacement.
- Maintenance history per asset: a signed maintenance record for every inspection supports audits and warranty claims.
Benefits of digitising forms in MapTrack
When you digitise generator checklists in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Email the right people when a form is submitted, with an automation you set up.
- File every completed form against the asset, location or person it covers.
- Download any completed form as a PDF, with failed answers listed at the top.
- Fill in forms offline; they upload when the device is back online.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Set who can view, fill in or edit forms with user roles.
- Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
- Raise a work order from a submitted form with an automation you set up.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
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Asset Coordinator, Saunders International
What to include in a generator maintenance checklist
This generator maintenance checklist covers 7 key areas:
- Generator details: generator ID, make/model, rated output (kVA/kW), fuel type, site/location, date, technician name, hour meter, last service date and hours.
- Visual inspection: external condition, fuel tank and lines (leaks, cap seal), exhaust system, air intake and filter, cooling system (radiator, hoses, fan, coolant level), battery and cables, control panel.
- Fluid checks: engine oil (level, condition, leaks), coolant (level, concentration, leaks), fuel level and quality (water/sediment), fuel filter/water separator condition.
- Electrical checks: battery voltage, charger operational, transfer switch (if fitted), circuit breakers, output connections, earth/ground connection, emergency stop.
- Operational test (under load): starts within normal cranking time, oil pressure, coolant temperature, voltage and frequency output stable, no abnormal noise or vibration, exhaust smoke colour, auto-start function (if fitted).
- Preventive maintenance due dates: next oil change, next fuel filter change, next air filter change, next coolant change, next load bank test.
- Defects and sign-off: defect description, reported to, generator fit for use, technician signature and date.
How to use this generator maintenance checklist
- Fill in generator details at the top of the form including the current hour meter reading and last service date.: Record the generator ID, make, model, rated output (kVA/kW), fuel type, site location and controller type. Include the current hour meter reading and the date and hours of the last service to confirm the maintenance interval.
- Complete the visual inspection with the generator at rest: check external condition, fuel system, exhaust, air intake, cooling system, battery and control panel.: Walk around the generator checking for external damage, fuel leaks at the tank, lines and fittings, exhaust rust or damage, air intake blockage, coolant leaks at hoses and the radiator, battery terminal corrosion and control panel warning indicators. Record findings for each system area.
- Check all fluid levels. Assess fuel quality for water or sediment contamination. Run the electrical checks including battery voltage, earth connection and emergency stop.: Check engine oil on the dipstick, coolant at the overflow tank and fuel level on the gauge. Draw a small fuel sample from the tank drain to check for water or sediment. Measure battery voltage with a multimeter, which should read 12.4V or above. Verify the earth connection is secure. Test the emergency stop from all accessible locations.
- Run the generator under load and record the output readings.: Start the generator, confirm it starts within normal cranking attempts and connect it to the building load or a load bank. Record voltage, frequency, oil pressure and coolant temperature under load, check for abnormal noise, vibration or exhaust smoke, and test the auto-start and load transfer if they are fitted.
- Record any defects, update the preventive maintenance due dates, and sign and date the form.: Describe each defect found, who it was reported to and whether the generator is fit for use. Update the preventive maintenance section with the next due dates for oil change, fuel filter, air filter, coolant change and load bank test. Sign and date the completed form.
In MapTrack, you can schedule and track maintenance digitally, by date or meter reading. Each submission is stored as a timestamped PDF against the asset record.
Get the free templateEnter your email above to download the full generator maintenance checklist as a PDF.Back to download formHow often should you complete this checklist?
Generator maintenance frequency should follow the manufacturer's manual and your site requirements. As a general guide: weekly visual inspections and oil level checks for active standby generators; monthly load testing for standby units to verify operational readiness; oil and filter changes every 200 to 500 running hours or annually (whichever comes first); coolant changes every 2 years or as specified; and load bank testing at the interval the manufacturer recommends (often annually; NFPA 110 sets an annual supplemental load test for diesel standby sets that cannot meet its monthly loading). Site generators running continuously require more frequent service intervals. Track hours and calendar dates in your maintenance system to ensure nothing is missed.
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Frequently asked questions
Applicable regulatory standards
This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| Model Work Health and Safety RegulationsMaintenance and inspection by a competent person following the manufacturer's recommendations. | Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
| Electrical installations - Generating setsElectrical installation of generating sets, including sets supplying safety and essential services. | AS/NZS 3010:2017 (incl. Amd 1:2020) |
| Standards Australia and Standards New ZealandSold by the publisher |
| Standard for Emergency and Standby Power SystemsWhere NFPA 110 applies: monthly exercise, the annual supplemental load test, Level 1 testing and records. | NFPA 110, 2025 edition |
| National Fire Protection Association (NFPA)Sold by the publisher |
| Occupational Health and Safety Regulations 2017 (Vic)Victoria's plant rules, which apply there instead of the model WHS Regulations. | Occupational Health and Safety Regulations 2017 (Vic), version 018 (in force from 20 October 2026) |
| Victorian Government (Victorian Legislation) |
Model Work Health and Safety Regulations
Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)
Maintenance and inspection by a competent person following the manufacturer's recommendations.
- reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
Safe Work Australia (drafted by the Parliamentary Counsel's Committee)
Electrical installations - Generating sets
Edition: AS/NZS 3010:2017 (incl. Amd 1:2020)
Electrical installation of generating sets, including sets supplying safety and essential services.
- 3.5: Additional requirements for permanently connected generating sets supplying safety and essential services
- Appendix D: Requirements and recommendations for the performance, construction and safety of transportable generating sets up to 25 kW
Standards Australia and Standards New ZealandSold by the publisher
Standard for Emergency and Standby Power Systems
Edition: NFPA 110, 2025 edition
Where NFPA 110 applies: monthly exercise, the annual supplemental load test, Level 1 testing and records.
- 8.4.2: Generators in service exercised at least monthly for at least 30 minutes, using one of the listed loading methods.
- 8.4.2.4: Diesel sets that cannot meet the monthly loading are exercised monthly and load tested annually with supplemental load at 50 and 75 percent.
- 8.4.9: Level 1 emergency power supply systems tested at least once in every 36 months.
- 8.5: Records of maintenance, inspection and testing of the emergency power supply system.
National Fire Protection Association (NFPA)Sold by the publisher
Occupational Health and Safety Regulations 2017 (Vic)
Edition: Occupational Health and Safety Regulations 2017 (Vic), version 018 (in force from 20 October 2026)
Victoria's plant rules, which apply there instead of the model WHS Regulations.
- Part 3.5: Plant: duties of designers, manufacturers, suppliers and employers who use plant, plus registration of designs.
- reg 105: Requires plant to be inspected as needed to monitor risks, and steps to be taken to prevent unauthorised alteration of, or interference with, the plant.
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
Generator maintenance checklist preview
The numbers behind this generator maintenance checklist
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<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Generator maintenance checklist</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Generator details: generator ID, make/model, rated output (kVA/kW), fuel type, site/location, date, technician name, hour meter, last service date and hours.</li>
<li style="margin:4px 0;">Visual inspection: external condition, fuel tank and lines (leaks, cap seal), exhaust system, air intake and filter, cooling system (radiator, hoses, fan, coolant level), battery and cables, control panel.</li>
<li style="margin:4px 0;">Fluid checks: engine oil (level, condition, leaks), coolant (level, concentration, leaks), fuel level and quality (water/sediment), fuel filter/water separator condition.</li>
<li style="margin:4px 0;">Electrical checks: battery voltage, charger operational, transfer switch (if fitted), circuit breakers, output connections, earth/ground connection, emergency stop.</li>
<li style="margin:4px 0;">Operational test (under load): starts within normal cranking time, oil pressure, coolant temperature, voltage and frequency output stable, no abnormal noise or vibration, exhaust smoke colour, auto-start function (if fitted).</li>
<li style="margin:4px 0;">Preventive maintenance due dates: next oil change, next fuel filter change, next air filter change, next coolant change, next load bank test.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/generator-maintenance-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Generator maintenance checklist</a> by MapTrack</p>
</div>Free to reuse, including commercially. This template is published under a Creative Commons Attribution 4.0 licence. Copy it, adapt it, put it on your own site or in your own docs. All we ask is that you credit MapTrack with a link back to this page. The snippet above already includes that credit, so if you use it as-is you’re covered.
Cite this template
Writing about this topic? You’re welcome to quote this checklist. Here’s the wording to use so your readers can find the original.
The MapTrack generator maintenance checklist contains 39 checks across 4 sections.
- Short attribution
- MapTrack Generator maintenance checklist, https://www.maptrack.com/templates/generator-maintenance-checklist
- Reference list
- MapTrack. (2026). Generator maintenance checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/generator-maintenance-checklist
Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/generator-maintenance-checklist.
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