Planned routine inspections help identify early signs of looseness, ageing, poor contact, contamination and abnormal heating. Determine inspection frequency using manufacturer manuals, operating hours, load changes, environmental conditions and maintenance records. A generic checklist cannot replace formal maintenance requirements.
Safety Preparations
- Shut down as specified for the equipment and isolate starting signals;
- Disconnect or isolate the supplies to be checked and confirm that stored energy has been safely released;
- Allow hot components to cool and avoid rotating, live or hot areas;
- Prepare insulated tools, lighting, cleaning materials and inspection records;
- Use qualified or experienced personnel for high-voltage, fuel, coolant or battery work.
Appearance, Mounting and Environment
Begin with a visual inspection without disassembly:
- Look for oil, water, dust, insects or foreign objects inside the generator set;
- Check controllers, AVRs, chargers, relays and terminal blocks for looseness, discolouration, cracks or unusual smells;
- Check mounting screws, brackets, grounding leads and vibration isolators;
- Confirm that ventilation openings, heat sinks and air passages are clear;
- Look for harness wear, compression, proximity to hot parts or oil contamination.
Stop operation and investigate further if burning, smoke, obvious deformation or damaged insulation is found.
Wiring and Connectors
Check terminals, connectors and harnesses, especially battery circuits, excitation circuits, sensors, actuators and control supplies. Do not infer function from wire colour alone. Before reconnecting, confirm against drawings, terminal numbers or reliable records.
For previously disconnected connectors, check latches, pins, seals and crimps. When measuring voltage or resistance, record the measurement location, operating condition, meter range and reference ground for later comparison.
Batteries and Chargers
- Check battery terminals for looseness, corrosion or abnormal heating;
- Check charger inputs, outputs, power indications and alarms;
- Where permitted, record resting voltage, charging voltage and voltage changes during starting;
- Confirm that battery voltage rating, charger current rating and operating mode match;
- \[Pending client input: inspection intervals and acceptance values for commonly used batteries and chargers\].
Controllers, Alarms and Operating Records
After power-on, check the controller display, date/time, operating hours, alarms and event records. Record abnormal codes rather than repeatedly clearing them before their cause is understood. Check the emergency stop, mode switch and required indicators. Test safety interlocks only using the manufacturer's procedure.
If communication or remote monitoring is supported, compare communication status and key readings with on-site instruments. Record who changed software, settings or wiring, when and why, and how to restore the previous state.
Voltage, Frequency and Regulation
Where safe test conditions exist, record output voltage, frequency, three-phase balance and fluctuations at no load and a representative load. If readings are abnormal, do not immediately turn AVR potentiometers or change control settings. First rule out speed, sensing, wiring, load and excitation system issues.
Electrical measurements may involve dangerous voltages and must be performed by professionals using suitable instruments and protective measures.
Cooling, Fuel, Lubrication and Filtration
Follow the generator set manufacturer's manual when checking coolant, lubricating oil, fuel, belts, hoses and filters. Leaks, blockages, ageing or abnormal levels can affect sensor readings and equipment protection. Do not replace an alarm-related component while overlooking a mechanical system cause.
Traceable Records
For each inspection, record:
- Date, operating hours and environmental conditions;
- Inspector and equipment status;
- Actual voltage, frequency, temperature, pressure and other readings;
- Alarm codes, photos, videos and corrective actions;
- Replaced parts, models, serial numbers and setting changes;
- Next inspection date and outstanding follow-up items.
Continuous records are more useful than a single reading and can reveal gradual deterioration.
Maintenance Intervals Awaiting Confirmation
\[Pending client input: daily, weekly, monthly and annual checks by equipment type, usage frequency, operating environment and critical parts.\]
\[Pending client input: available on-site inspection, remote diagnosis or scheduled maintenance services.\]
This checklist is for general information only. Actual checks, intervals, limits and replacement criteria must follow the equipment and part manufacturers' official manuals, local requirements and on-site risk assessment.