Generator Testing Intervals

Cosumables

1. Inspect fuel tank, must be a 2-hour minimum
2. Inspect lubircating oil
3. Inspect engine coolant level
4. Inspect engine, generator, fuel tank(s), and cooling system for leakage
5. Inspect fuel transfer pump operations (if applicable)
6. Inspect fuel filter for contamination if equipped with inspection bowl

Starter System

1. Inspect electric starter for cleanliness, mounting, and terminal torque
2. Inspect air tanks for pressure 
3. Inspect valves for leakage
4. Test auxiliary engine and compressor for proper operation
5. Bleed off any condensation

Batteries and charging equipment

1. Inspect electric starter for cleanliness, mounting, and terminal torque
2. Inspect all battery cells for correct electrolyte levels
3. Test all batteries for correct specific gravity
4. Inspect electrical connections for tightness and evidence of corrosion
5. Inspect batteries for cleanliness and dryness between terminals
6. Inspect charger electrical connections for cleanliness and tightness
7. Test charger for proper operation of float and equalize modes

Engine

1. Test lubricant and/or coolant heaters for proper operation
2. Inspect governor control linkages and oil level
3. Inspect fuel pump sump (if applicable)
4. Inspect fan belts for correct tension and wear

Control Panel

1. Inspect Control Panel covers for security
2. Test annunciator lamps to confirm they are operational
3. Inspect control panel settings, ensuring the unit if set to automatic start-up
4. Test remote visual and audible trouble signals at the building fire alarm panel

Misc

1. Inspect air control louver settings to ensure proper operation
2. Test emergency lighting unit(s)
3. Verify room temperature is above 10 degrees C
4. Inspect generator and transfer switch rooms for cleanliness and accessibility to all components of the emergency system
5. Correct all defficiencies found during inspection
6.  Record all inspections, tests, and corrective actions in the log

1. Complete all weekly inspections items listed above
2. Simulate a failure of normal electrical supply to the building
3. Operate the system under at least 30% of the rated load for 60 minutes
4. Operate all automatic transfer switches under load
5. Insect brush operation for sparking
6. Inspect bearings seal leakage
7. Inspect for correct operation of all auxiliary equipment. ex. radiator shutter control, coolant pumps, fuel transfer pumps, oil coolers, and engine room ventilation
8. Record all readings for all instruments in the log, and verify they are normal
9. Drain the exhaust system condensate trap
10. Inspect all block heater hoses and wires
11. Correct all defects found during inspections and tests
12. Record all inspections, tests, and corrective actions in the log 

1. Complete all items in weekly inspections and tests above 
2. Complete all items in Monthly inspections and tests above
3. Inspect and clean engine crank case breathers
4. Inspect and clean all engine linkages
5. Lubricate the engine governor and ventilation system 
6. Test protective devices for proper operation
7. Perform a battery load test with appropriate Load Test meter on batteries, ensuring they are above 80% of rated voltage. If not above 80% replace batteries.
8. Inspect ventilation system belts
9. Correct all defects found during inspection and tests
10. Record all inspections, tests, and corrective actions in the log

1. Complete all items in weekly inspections and tests above 
2. Complete all items in Monthly inspections and tests above
3. Complete all items in Semi-Annual inspections and tests above
4. Open all  inspection covers and inspect all electrical connections
5. Test breakers for proper operation
6. Clean insulators and bushings
7. Test voltage regulator for proper operation
8. Operate all moving parts to ensure they move freely
9. Clean and dress contacts as necessary
10. Remove all dust 
11. Check gauge calibration
12. With the gen-set operating at full load perform a thermographic analysis to identify any high resistance connections
13. For off-site fuelled generators, turn position-indicating gas valve to off position to ensure valve rotates properly and the audible alarm activates on the generator and Fire Alarm panel
14. Change engine lubrication oil and filters 
15. Test coolant and chemical protection level of coolant inhibitors
16. Change fuel filters, clean strainers, and verify fuel supply valve is open
17. Clean and lubricate linkages
18. Inspect air filters
19. Inspect all mechanical connections
20. Inspect all electrical connections
21. For spark ignition engines, inspect all components of ignition system and service or replace as appropriate 
22. Inspect all external surfaces of heat exchangers and clean as necessary
23. Inspect all belts and hoses and replace any defective components
24. Inspect coolant pumps for leaks and external wear
25. Visual inspection of fuel following the clear and bright test, if fuel fails test, fuel must be drained and replaced or filtered and cleaned
26. Test surge suppressor and rotating rectifier on brushless machines
27. Grease bearings
28. Clean communicator and slip rings
29. Clean rotor and stator windings using clean compressed air
30. Inspect couplings bolts and alignment
31. Inspect conduits for tightness
32. Inspect windings at rotor and stator slots
33. Inspect all electrical connections
34. With gen-set operating at full load perform Thermographic analysis of electrical connections to identify any high resistance connections
35. Isolate transfer switch, open all inspection covers, and inspect all electrical connections
36. Operate all moving parts to ensure that they move freely
37. Clean and dress contacts as required
38. Remove all dust
39. Clean and lubricate linkages
40. Conduct an infrared survey of all electrical components, contacts, and energized components while under load on both normal and the emergency side
41. Lubricate door locks and hinges if required
42. Conduct a 2-hour full load test
43. Correct all defects found during inspections and tests
44. Record all inspections, test, and corrective actions in the log

1. Perform all inspections and test for Weekly, monthly, Semi-Annual, and Annual inspections
2. Inspect insulation of generator windings. Use a insulation resistance tester (Megger), the resistance shall not be less than Rated voltage+1000/1000. If less dry out the insulation using auxiliary heat source
3. Drain and flush the cooling system. Refill the system with new coolant
4. Clean radiator tubes and cooling fins
5. Replace thermostat
6. Inspect valve clearances and adjust as appropriate
7. Correct all defects found during inspections and tests
8. Record all inspections, tests, and corrective actions in the log