Generator Maintenance Checklist

A diesel generator that gets scheduled preventive maintenance lasts 15–20 years. One that gets none typically needs a major overhaul at 5–7. Here is the exact checklist Mecwel Engineers technicians run on Greaves DG sets across Guwahati and Assam.

Weekly checks (owner or operator)

• Visual inspection for leaks — oil, coolant, fuel
• Check engine oil level on dipstick
• Check coolant level in radiator overflow bottle
• Check fuel level and drain any water from fuel sedimenter
• Battery terminal cleanliness and voltage (should read 13.5–14.4 V with charger on)
• Test-run the DG on load for 15–20 minutes (crucial — no-load running glazes cylinders)
• Note any unusual smoke, sound or vibration

Monthly checks

• Clean air filter (replace if paper element is damaged)
• Inspect fan belt tension and cracks
• Check all electrical terminations for tightness
• Clean control panel and check indicators
• Grease alternator bearings (if grease nipples fitted)
• Wipe canopy and check acoustic foam condition

Every 250 running hours or 6 months (technician)

• Change engine oil and oil filter
• Change fuel filter
• Change fuel sedimenter element
• Check and adjust valve clearance if noisy
• Radiator external cleaning
• Load test at 80% rated load for 1 hour

Every 500 running hours or annually

• Change air filter element
• Coolant test (pH, freeze point, corrosion inhibitor level) — replace every 2 years
• Turbocharger inspection
• Injector spray-pattern test
• Battery load test — replace if capacity below 70%
• Alternator megger test
• AVR calibration
• Earthing continuity and resistance test

Every 1,500–2,000 hours

• Valve clearance re-adjustment
• Fuel injector cleaning and calibration
• Governor inspection
• Alternator bearing replacement

Major overhaul (typically 8,000–10,000 hours)

• Cylinder head inspection and lapping
• Piston ring replacement
• Bearing shells and crankshaft measurement
• Turbocharger overhaul
• Full recalibration and load-bank test

What an AMC covers

Instead of tracking all this in-house, most Guwahati businesses hand it to Mecwel Engineers on an Annual Maintenance Contract. Comprehensive AMCs cover labour + genuine Greaves spare parts + priority breakdown response, so the only thing your team monitors is the weekly checklist above.

Ready to power your business? Get a free quote from Mecwel Engineers — Guwahati's authorized Greaves Cotton dealer since 1991. Call +91 97060-11988 for on-site load survey and pricing across Assam.