A generator set is mainly composed of an engine, alternator, control system, fuel system, cooling system, and exhaust system. During operation, the engine converts fuel energy into mechanical power, and the alternator then converts mechanical power into electrical energy for output.
To keep the generator set safe and efficient, routine inspection and maintenance should be carried out according to operating hours and load conditions.
Routine Inspection (Daily / Before Start)
- Check appearance, wiring, and connections; confirm there is no looseness or damage.
- Run at no-load for 5-10 minutes and observe startup performance and operating stability.
- Check cooling system, lubrication system, and fuel system for leakage.
- Monitor key indicators such as voltage, current, frequency, and water temperature.
- Check battery status and charging condition.
- After shutdown, clean visible dust and inspect for abnormal odors or noise records.
Level-1 Maintenance (about every 50-100 hours)
- Clean intake and exhaust filters and basic dust buildup around the unit.
- Inspect and tighten external fasteners and electrical terminals.
- Check belt tension and wear condition.
- Inspect lubricating oil and coolant status; replenish when required.
- Verify normal operation of protection functions and control alarms.
Level-2 Maintenance (about every 250-300 hours)
- Include all Level-1 items and perform deeper cleaning of cooling and fuel circuits.
- Replace or clean fuel filter and oil filter according to service condition.
- Inspect water pump, thermostat, and key piping for reliability.
- Check injector condition and fuel spray quality; calibrate when necessary.
- Inspect alternator insulation and wiring condition to ensure electrical safety.
Level-3 Maintenance (about every 500-1000 hours)
- Include all Level-1 and Level-2 maintenance items.
- Conduct comprehensive engine performance inspection and key component servicing.
- Check compression, valve clearance, and core moving parts if required.
- Review and verify full operating records to optimize preventive maintenance planning.