A diesel generator set preventive maintenance schedule lists the checks and jobs done on the equipment at fixed intervals, how long each takes, and in what order of frequency, so problems are found before the diesel generator set fails. This page gives the schedule used in the PlantOps360 task library for diesel generator set (set), which follows common industry practice for general-purpose equipment. It is also searched for as DG set, diesel generator, genset, generator set.
The maker’s manual and your site safety procedures always come first where they differ. Intervals set by law differ by state.
Diesel generator set preventive maintenance schedule and checklist
| How often | Task | Estimated time |
|---|---|---|
| Daily | Check engine oil, coolant and fuel level; check battery, belts and for leaks before starting | 10 min |
| Weekly | Start the set and run it for 15 to 30 minutes (on load where possible); record voltage, frequency, oil pressure and temperatures | 20 min |
| Weekly | Drain water from the fuel tank and fuel-water separator; check starting battery and charger | 15 min |
| Monthly | Check air filter, radiator, hoses and belts; check exhaust system and for leaks | 45 min |
| Monthly | Exercise the set on a load of at least 30% of its rating for at least 30 minutes | 45 min |
| Quarterly | Test automatic mains failure (AMF) panel and change-over operation | 90 min |
| Half-yearly | Change engine oil and oil filter; replace fuel filters (earlier if operating hours dictate) | 150 min |
| Annual | Annual service: coolant condition, valve clearance check, injector check, alternator insulation test and load bank test | 480 min |
| Annual | Check the acoustic enclosure, exhaust silencer and stack; arrange emission and noise monitoring as per the consent conditions | 120 min |
Diesel generator set maintenance frequency and yearly workload
At the estimated times, one diesel generator set needs about 130 hours of preventive maintenance a year. The biggest single job is “Annual service: coolant condition, valve clearance check, injector check, alternator insulation test and load bank test” at 480 minutes, done annual. Multiply by the number of units you have to see the workload for your plant.
| Frequency | Tasks | Time per round | Hours per year |
|---|---|---|---|
| Daily | 1 | 10 min | 60.8 h |
| Weekly | 2 | 35 min | 30.3 h |
| Monthly | 2 | 90 min | 18.0 h |
| Quarterly | 1 | 90 min | 6.0 h |
| Half-yearly | 1 | 150 min | 5.0 h |
| Annual | 2 | 600 min | 10.0 h |
What goes wrong on a diesel generator set without preventive maintenance
- Weak starting battery or faulty charger
- Water or contamination in the fuel
- Coolant, belt and hose problems
- An AMF panel or change-over that has not been tested
What to watch between services
- Battery voltage and charger output
- Fuel level and water in the separator
- Oil pressure, coolant temperature, voltage and frequency on the weekly run
Safety and statutory notes for diesel generator set maintenance
Emission and noise monitoring for DG sets is usually a condition of the pollution control board consent. Check the conditions in your own consent.
Where a diesel generator set preventive maintenance schedule is used
A diesel generator set is found in almost every industry. The industry guides below show how it fits into the wider schedule of each one:
- Preventive maintenance schedule for pharmaceutical plants
- Preventive maintenance schedule for food, dairy and beverage plants
- Preventive maintenance schedule for automotive plants
- Preventive maintenance schedule for chemical, fertiliser and petrochemical plants
- Preventive maintenance schedule for cement, glass, ceramics and building materials plants
- Preventive maintenance schedule for steel, foundry, forging and metal plants
- Preventive maintenance schedule for textile and garment mills
- Preventive maintenance schedule for thermal and hydro power plants
See all industry preventive maintenance schedules.
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Browse the full list of equipment preventive maintenance schedules (317 types).
Run this diesel generator set schedule in maintenance software
In preventive maintenance software, each row above becomes a recurring task on the asset with its checklist, time estimate and parts. Tasks can be triggered by calendar date, running hours, meter readings or production cycles, each completed task is recorded with the person and date, and a failed check can open a work order. For the method behind it, read the guide to the preventive maintenance schedule, or use the free generator to get a 12-month plan for your whole equipment list.
Build my preventive maintenance schedule (free Excel)
Frequently asked questions
How often should a diesel generator set be serviced?
In our schedule a diesel generator set has 9 tasks: 1 daily, 2 weekly, 2 monthly, 1 quarterly, 1 half-yearly, 2 annual. The biggest job is “Annual service: coolant condition, valve clearance check, injector check, alternator insulation test and load bank test”, which is done annual. Always follow the maker’s manual where it gives a different interval.
What is included in diesel generator set preventive maintenance?
It covers routine checks and jobs such as “Check engine oil, coolant and fuel level; check battery, belts and for leaks before…”, “Start the set and run it for 15 to 30 minutes (on load where possible); record voltage…”, “Drain water from the fuel tank and fuel-water separator; check starting battery and…”, up to the annual overhaul or inspection. The full list with times is in the table above.
How many hours of maintenance does a diesel generator set need per year?
About 130 hours per unit per year at the estimated times in our library, including the daily checks done every day. Use it to plan workload, not as a benchmark.
Is there a free diesel generator set maintenance checklist?
Yes. The table on this page is a ready checklist. The free preventive maintenance schedule generator turns it into a 12-month Excel schedule for your list of equipment, with monthly workload hours.