PM planOfficial FreeMaint

Standby diesel generator six-monthly maintenance plan

Six-monthly plan for a standby diesel generating set: fluids, belts, battery and charger, fuel, air, exhaust and block heater, a run under load and a transfer switch test; oil and filters changed and a fuel sample taken once a year.

11 tasksGenerators and powerVersion 1Updated

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What’s inside

Schedule

Every 6 months

  • Fixed calendar: the next date does not move with the completion date.
  • Work order window: 14 days
Estimated duration: 3 hPriority: High

Imported inactive and without equipment: assign it to your assets, set its start date (the first due date), check the intervals against the manufacturer’s manual, then switch it on.

Tasks at each service

  1. Prevent an automatic start before working on the set

    Warn the site that standby power is unavailable, set the controller to OFF or maintenance mode, and disconnect the starting battery and the battery charger before working on the engine.

    Action5 min

    Risks: A standby set starts on its own when the mains fails: never work on it while the controller is in AUTO.

  2. Check the engine oil and the coolant

    Check the engine oil level and look for leaks. Check the coolant level and measure its freeze protection with a refractometer, against the lowest temperature expected on site.

    Measurement15 min

    Tools: Coolant refractometer

    Risks: Never open the radiator cap on a hot engine.

  3. Inspect the belts and the hoses

    Check the drive belts for cracks, wear and tension, and the coolant and fuel hoses for cracks, swelling and loose clamps.

    Inspection10 min

  4. Check the starting battery

    Clean and tighten the terminals, check the electrolyte level where the battery allows it, and measure the battery voltage.

    Measurement15 min

    Tools: Multimeter

    Risks: Wear eye protection; no flame or spark near the battery.

  5. Check the fuel system

    Check the tank level against the autonomy required on site, drain the water from the fuel water separator, and look for leaks on the lines and the day tank.

    Inspection15 min

  6. Check the air intake, the exhaust and the block heater

    Check the air filter restriction indicator, the exhaust for leaks and the condensate drain, the rain cap, and that the block heater keeps the engine warm.

    Inspection10 min

  7. Change the engine oil and the oil, fuel and air filters

    Once a year, or sooner if the engine reaches the running hours given in its manual. Use the oil grade and quantity of the manufacturer and dispose of used oil and filters as hazardous waste.

    Action60 minonce every 2 services

  8. Take a fuel sample

    Take a sample from the bottom of the tank and check it for water, sludge and microbial growth; have the tank cleaned or the fuel treated if it is contaminated.

    Inspection10 minonce every 2 services

  9. Run the set under load

    Reconnect the battery and the charger, start the set and run it on load, typically for at least 30 minutes or as long as your site procedure requires. Record the voltage, frequency, oil pressure, coolant temperature and load, and look for leaks, smoke and abnormal noise.

    Measurement40 min

    Risks: Wear hearing protection near a running engine. Keep the enclosure doors closed around rotating parts.

  10. Test the automatic transfer switch

    With the site’s agreement, simulate a mains failure and check that the set starts, the load transfers within the required time, then returns to the mains and the set cools down and stops.

    Verification20 min

  11. Leave the set in AUTO and record the readings

    Check that the controller is back in AUTO with no active alarm, the charger is on and holds the float voltage given by its manufacturer, and the block heater is powered, then record the readings and the hour meter in the work order.

    Verification5 min

Parts (indicative)

  • Engine oil filter × 1
  • Fuel filter × 1
  • Air filter element × 1

Tools (indicative)

  • Coolant refractometer
  • Multimeter
  • Fuel sampling bottle — Yearly fuel sample
  • Hearing protection

Indicative list: on import it is written into the plan’s description, to link to your own inventory.

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Licence

Official FreeMaint template, free to use and adapt inside your FreeMaint workspace. An adaptation may be shared in the library under CC BY 4.0; its page then credits this template.

Templates are general guidance. They do not replace the manufacturer’s instructions, your site procedures or applicable regulations.

Equipment: Generators and power

Industries: Healthcare, Facilities, Manufacturing, Energy and utilities, Hospitality

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