The stable operation of generators is a crucial guarantee for both enterprise production and emergency power supply. However, neglecting daily maintenance may lead to significant losses in the event of a failure. The following 10 inspection points, summarized by an experienced equipment maintenance team, help you identify potential risks in just 15 minutes and avoid the passive situation where “power failure equals production shutdown.”
1.Oil Level Monitoring: Don’t Let the Engine “Run Dry”
Open the oil dipstick and check if the oil level is between the “MIN” and “MAX” markings. If the oil appears cloudy or contains metal particles, replace it immediately—this could be an early sign of internal wear. Tip: Measure after stopping the machine for 10 minutes for more accurate readings.
2.Cooling System: High Temperature is an Invisible Killer
Insufficient coolant can lead to engine overheating and failure. Check the water level in the auxiliary water tank and confirm the color through the observation window (usually green/red). In winter, test the freezing point to prevent freezing in low temperatures. Note: Never open the cap when the engine is hot!
3.Battery: 90% of Startup Failures Are Caused by This
Use a multimeter to measure the voltage: it should be ≥12.6V (for a 12V battery) when idle. Check if the terminals are white—that’s a sign of sulfation, which can be cleaned with a wire brush dipped in baking soda water. For batteries left unused for long periods, it’s recommended to disconnect the negative terminal.
4.Belt Tension: Loose Belts Slip, Tight Belts Break Shafts
Press the middle of the belt with your thumb, and the deflection should be between 10-15mm. Check for cracks: if more than three longitudinal cracks are found, replace the belt. Tip: Recheck and adjust the tension after 200 hours of running with a new belt.
5.Air Filter: Restricted Breathing Affects Power
Remove the filter and hold it up to a light source; if more than 30% of the area is opaque, use compressed air (pressure ≤5bar) to blow from the inside out. Paper filters should be replaced every six months, with more frequent replacements in desert areas.
6.Fuel System: Leaks Can Cause Fires
Focus on checking for oil stains around the fuel pump interface and filter. Diesel engines require daily draining of the water separator, and gasoline engines should ensure the fuel tank vent is clear. Warning: if you smell a strong oil odor, stop the machine immediately and investigate!
7.Output Terminals: Loose Connections Equal Power Loss
Use an infrared thermometer to scan the terminal connections; if the temperature difference is greater than 10°C, it indicates poor contact. After tightening bolts, apply anti-oxidation grease to reduce arc corrosion. For standby generators, it’s recommended to run them with load for 30 minutes every month to prevent terminal oxidation.
8.Control System: Hidden Hazards Behind the Indicator Lights
Before starting, check the instrument panel for fault codes, and press and hold the “reset” button for 3 seconds to clear historical alarms. Test the emergency shutdown button response time—ensure it completely shuts down the engine within 5 seconds.
9.Machine Vibration: Strange Noises are the “Language” of Faults
Place a coin upright on the machine shell while it’s running; if it falls over, the vibration is excessive. Listen to the running sound: a crisp “click-click” sound is normal, while a dull “thud-thud” may indicate worn crankshaft bearings.
10.Environmental Preparation: 80% of Failures Could Be Prevented
Clean up the area within 2 meters of the generator to ensure the air intake is unobstructed. Check the fire extinguisher pressure gauge to ensure it is in the green zone, and make sure the sand bucket has enough supply to cover the fuel tank area. In the rainy season, elevate the base by more than 15cm to prevent water accumulation.
Final Reminder After each inspection, make sure to fill out the “Maintenance Log” and record key data such as oil level and voltage. There was a case where a power station failed to register the consumption of coolant in time, leading to a slow leak that eventually caused a 200,000 RMB generator unit to be scrapped. Detailed management is the core competitive advantage of emergency equipment maintenance.