47-Point Generator Maintenance Checklist

Why Maintenance Matters

A well-maintained generator can last 20,000+ hours. Neglected ones fail at 5,000 hours. That's the difference between 20 years and 5 years of service.

Our 47-point checklist covers everything you need to keep your generator running perfectly.

DAILY CHECKS (5 minutes)

Do these every day your generator runs:

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Visual Inspection 1. ✅ Check for oil leaks under and around the generator 2. ✅ Look for fuel leaks around connections and filters 3. ✅ Check coolant level in reservoir (don't open hot radiator!) 4. ✅ Inspect battery terminals for corrosion 5. ✅ Verify all guards and covers are in place

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Operational Checks 6. ✅ Check oil level with dipstick (should be between marks) 7. ✅ Verify fuel level is adequate 8. ✅ Listen for unusual sounds during operation 9. ✅ Check exhaust color (should be clear or light gray) 10. ✅ Monitor control panel for warning lights

WEEKLY CHECKS (15 minutes)

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Engine System 11. ✅ Check air filter condition (hold up to light - should see through) 12. ✅ Inspect drive belts for cracks, fraying, proper tension 13. ✅ Check radiator fins for debris/damage 14. ✅ Verify coolant hoses are tight and not cracked 15. ✅ Test battery voltage (should be 12.5V+ when off, 14V+ charging)

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Fuel System 16. ✅ Drain water separator/fuel filter 17. ✅ Check fuel lines for cracks or leaks 18. ✅ Verify fuel tank vent is clear 19. ✅ Inspect fuel cap seal

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Electrical 20. ✅ Check all cable connections are tight 21. ✅ Verify ground connection is secure 22. ✅ Inspect control panel for any loose wiring 23. ✅ Test emergency stop button functions

MONTHLY CHECKS (30 minutes)

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Deep Inspection 24. ✅ Clean air filter or replace if damaged 25. ✅ Check alternator belt tension and condition 26. ✅ Inspect exhaust system for leaks 27. ✅ Clean battery terminals and apply protector 28. ✅ Check ATS (Automatic Transfer Switch) operation

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Testing 29. ✅ Run generator under load for 30 minutes minimum 30. ✅ Check all gauges: oil pressure, water temp, voltage, frequency 31. ✅ Test automatic start function (if equipped) 32. ✅ Verify output voltage under load (should be 240V ±5%) 33. ✅ Check frequency stability (should be 50Hz ±1Hz)

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Documentation 34. ✅ Record running hours 35. ✅ Log fuel consumption 36. ✅ Note any observations or concerns 37. ✅ Update maintenance log

QUARTERLY CHECKS (1-2 hours)

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Oil & Filters 38. ✅ Change engine oil (or at manufacturer intervals) 39. ✅ Replace oil filter 40. ✅ Replace fuel filter(s) 41. ✅ Replace air filter element

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Cooling System 42. ✅ Test coolant concentration with refractometer 43. ✅ Check thermostat operation 44. ✅ Clean radiator externally 45. ✅ Inspect water pump for leaks

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Electrical System 46. ✅ Test battery load capacity 47. ✅ Check starter motor engagement

SERVICE INTERVALS TABLE

Component Interval Notes | |

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-| Engine oil 250 hours or 6 months Use manufacturer grade | Oil filter Every oil change Quality filters only | Fuel filter 500 hours or annually Check monthly | Air filter 500 hours or as needed Clean weekly | Coolant 2,000 hours or 2 years Use proper mix | Spark plugs (petrol) 500 hours Gap to spec | Injectors (diesel) 2,000 hours Professional service | Valve adjustment 2,000 hours Professional service | Full overhaul 10,000-15,000 hours Major service |

WARNING SIGNS - CALL US IMMEDIATELY

🚨 Engine:

Blue or black exhaust smoke

Knocking or unusual sounds

Oil pressure drops below normal

Excessive vibration

🚨 Electrical:

Output voltage fluctuations >10%

Frequency instability

Warning lights staying on

Burning smell from control panel

🚨 Cooling:

Coolant leaking

Temperature above normal

Coolant discolored or oily

Radiator damage

🚨 Fuel:

Diesel in oil (dipstick smells like fuel)

Black smoke

Hard starting

Fuel consumption increased

COMMON MAINTENANCE MISTAKES

1. Ignoring the air filter - Dirty filter kills engines faster than anything 2. Wrong oil type - Always use manufacturer-specified grade 3. Skipping load tests - Generators need regular exercise 4. Letting fuel sit - Diesel degrades, use stabilizer for storage 5. Ignoring small leaks - Today's drip is tomorrow's failure 6. DIY injector work - Always use professionals for fuel injection 7. Cheap filters - Genuine/quality filters protect your investment

STORAGE PROCEDURES

If not using for extended periods:

1. Run generator for 30 minutes at load to warm thoroughly 2. Drain fuel or add stabilizer (follow directions) 3. Change oil while engine is warm 4. Fog engine if storing 3+ months 5. Disconnect battery and store separately 6. Cover generator but allow ventilation 7. Run monthly for 30 minutes under load

FREE MAINTENANCE SERVICE

Emerson Energy offers comprehensive maintenance packages:

Package Coverage Price | |

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-| Basic Quarterly service, parts extra KES 8,000/year | Standard Quarterly + emergency calls KES 15,000/year | Premium Monthly visits + all parts KES 35,000/year | Enterprise 24/7 coverage + priority Custom quote |

All packages include:

Certified technicians

Genuine/OEM parts

Detailed service reports

WhatsApp support

Schedule Your Service

📞 Call: +254 768 860 665 or +254 782 914 717 📍 WhatsApp: Send your generator model for instant quote 🏠 Coverage: All 47 counties in Kenya

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*Keep this checklist handy! Print it and post near your generator.*

*Emerson Energy - Expert generator maintenance since 2005*