Attachment A.pdf

Attachment A I. General Preventive Maintenance and Inspection Requirements:

Facility will determine the frequency of service. At the discretion of the facility, maintenance must include but will not be limited to the following:

A. Engine and Mounting

1. Verify and record oil pressure and water temperature.

2. Test all safety shutdown circuits and alarms (over speed, over crank, low oil pressure, high water temperature low coolant level).

3. Inspect air intake system (air filter, crankcase breather, and turbocharger).

4. Inspect mu ler system and drain condensation trap; verify rain cap operation.

5. Inspect engine starting system; verify cable integrity and connections.

6. Inspect exhaust flex coupling and piping for leaks and proper connection.

7. Check for abnormal vibration or noise.

8. Inspect spark plugs, plug wires and distributor.

9. Check ignition system.

10. Check and clean injector pump and injector flow rate, pressure and spray pattern.

11. Check valve clearance.

12. Check bolt torque.

B. Fuel System

1. Inspect all fuel lines and hoses for leaks and general condition.

2. Inspect day tank and float assembly for proper operation and leaks.

3. Inspect fuel pump for leaks.

4. Verify proper operation of governor and governor linkage.

5. Check fuel level in primary supply tank.

6. Drain water and sediment from fuel filter and fuel supply tanks.

7. Adjust engine idle speed setting and electric governing system; check for proper governor operation.

8. Change fuel filter element and drain out sediment.

9. Check hydraulic governor oil level; change if necessary.

C. Coolant System

1. Inspect all clamps, verify condition of all hoses and identify any leaks.

2. Verify proper operation of engine water jacket heater.

3. Test coolant freeze point and verify coolant level.

4. Test coolant additive package for proper corrosion inhibitors.

5. Inspect belt condition and tension; correct as required.

6. Inspect radiator core for visual blockage or obstructions.

7. Inspect for proper operation of intake louvers.

8. Verify proper operation of remote radiator and belt condition.

9. Coolant flush.

D. Battery and Battery Charger System

1. Clean all battery terminals; verify integrity of cables and connectors.

2. Load-test battery.

3. Measure specific gravity of each battery cell.

4. Inspect electrolyte level and add fluid if necessary.

5. Verify proper operation and float voltage of external battery charger.

6. Verify and record output of engine alternator.

E. Controls

1. Verify and record output voltage and adjust voltage regulator, if necessary.

2. Calibrate control meters.

3. Verify and record output frequency and adjust governor, if necessary.

4. Verify operation of all control panel lamps.

5. Inspect for any loose connections, terminals or discoloration.

F. Lubricating System

1. Check for oil leaks.

2. Check oil and change if necessary.

3. Change filter element; clean if screen-type.

4. Lubricate generator, cranking motor, water pump and fan hub, if needed.

5. Run engine and check for proper oil pressure, fuel oil pressure, oil/water temperatures, density and exhaust gas color.

6. Inspect engine external for worn parts.

7. Check engine exhaust system for leakage.

G. Generator

1. Inspect and lubricate generator end bell bearing.

2. Inspect brushes, brush holders and commutators.

3. Inspect cooling screen and general condition of alternator.

4. Inspect for abnormal vibration.

5. Verify connections and insulation condition.

6. Verify proper operation of shunt trip on mainline circuit breaker.

7. Check rotor and starter.

8. Check and clean voltage regulator.

9. Check and clean exciter.

H. Automatic Transfer Switch (Paralleling Switchgear, Bypass Switchgear, Manual Transfer Switches)

1. Verify proper operation of exerciser clock; adjust if necessary.

2. Provide visual inspection of all contacts and connection points.

3. Perform building load test if practical and inspect for proper transfer and re-transfer.

4. Verify operation of all control lamps.

I. Other

1. Check AC generator brushes and commutator.

2. Check battery (s) and add water, if necessary.

3. Check battery charger and adjust, if necessary.

4. Check automatic transfer switch(es), clean enclosure, lubricate moving components.

5. Check circuit breaker and check stator leads to breaker for loose connections.

6. Check voltage regulator and voltage adjust rheostat.

7. Check vibration isolators.

8. Check automatic start panel for proper operation.

9. Check and clean rotating exciter.

10. Check full bridge rectifier and exciter, clean same.

11. Check all stator leads for insulation breakdown.

12. Check all wiring and all safety shutdowns for loose connections.

13. Check Direct Current (DC) alternator for proper operation.

14. Check all engine wiring and Alternating Current (AC) wiring for burned and/or loose connections, repair or replace.

15. Run unit under load, check operations of switch gear and auto-start.

16. If acceptable by the Facility personnel, operate system to check full sequence of operation.

17. Record settings of temperature control switch and adjust for winter or summer operation.

18. Change lube oil.

19. Change primary and bypass lube filters.

20. Change fuel filters.

21. Change water filters.

II. Quarterly Preventive Maintenance and Inspection Requirements:

Quarterly service, when requested, will consist of the following:

A. Cooling System

1. Visual Inspection of Radiator/Heat Exchange for leaks, damage and obstruction.

2. Add Coolant (up to four (4) gallons) to bring the coolant to correct level.

3. Inspect condition of radiator cap, gasket and sealing surface.

4. Visual Inspection of water pump and cooling system gaskets for leaks.

5. Inspect belts for cracking and fraying.

6. Check jacket water heater(s) for proper operation and adjust thermostat setting as needed.

7. Check belt tension.

8. Inspect flexible water connections for crackling, leaks and pliability.

B. Lubrication System

1. Add crankcase oil (up to two (2) gallons of oil meeting or exceeding manufacturer’s specifications. a. Such as API CH-4, CG 4, CF-4 or Natural Gas oil if spark ignited) to bring the oil to its correct level.

2. Inspect Oil heater for proper operation and leaks.

3. Check for excessive crankcase blow-by with engine running.

4. Visual inspection front and rear crankshaft seals and lubrication system gaskets for leaks.

C. Fuel System

1. Inspect flexible fuel lines for cracking, leaks and pliability.

2. Test day tank pump for proper operation and level.

3. Operate fuel priming pump and check for proper operation and leaks.

4. Drain water from water separator.

5. Check fuel system for leaks.

6. Check Governor Oil level in main fuel tank.

7. Record fuel level in main fuel tank.

D. Starting System

1. Top o electrolyte level.

2. Check and record battery charger amperage.

3. Check battery charger and adjust float rate for optimum battery performance and life.

4. Check and record alternator for proper charge rate with engine running.

5. Check for proper cranking termination upon starting.

E. Exhaust System

1. Inspect flexible exhaust coupling for cracks and excessive leakage.

2. Check for abnormal exhaust characteristics with engine running (signs of wet stacking).

3. Inspect exterior of exhaust manifolds for oil/fuel slobber (signs of wet stacking).

4. Inspect exhaust rain protection and exhaust outlet screening.

F. Air Intake System

1. Inspect air filters for plugging and deterioration.

G. Installation

1. Make walk around inspection of complete installation.

2. Inspect generator set vibration isolators and adjust as needed.

3. Check for unit on-line capability in less than ten (10) seconds.

4. Check for abnormal noise or vibration.

5. Re-Check oil level with engine running.

6. Re-Check for leaks with engine running.

7. Check for proper operation of remote fan motors, thermostats, circulating pumps and solenoid valves.

8. Check inlet and discharge louvers for proper operation with engine running and stopped.

H. Control Panel

1. Operational check of illumination and safety lamps.

2. Check proper operation of engine and generator instruments with generator running.

3. Adjust Governor Control for optimum performance and frequency.

4. Adjust voltage regulator for proper voltage.

I. Upon Completion of Service

1. Reset all controls to automatic.

2. Set circuit breaker to correct position.

3. Check fuel valves for correct position.

4. Check voltage regulator is on and NOT tripped.

5. Check battery charger is ON.

6. Check day tank controls are ON.

7. Louver controls are ON.

8. Jacket Water Heater(s) are ON.

9. Remote Radiator Fan Controls are ON.

10. Auxiliary water pump controls are ON.

11. Cooling System

a. Inspection of pulleys for excessive wear.

12. Fuel System

a. Inspection of steel fuel lines for cracks, leaks and proper line bracket support.

b. Check the main tank for water (if accessible).

13. Starting System

a. Clean and apply corrosion inhibitor to the terminals of lead acid batteries as needed.

b. Tighten battery cable connections as needed.

c. Inspect and tighten starter motor(s), connections and wiring.

14. Exhaust System

a. Drain water in exhaust moisture traps.

b. Inspect exhaust manifold(s) for broken or missing hardware.

15. Air Intake System

a. Test air cleaner indicator. XVII. Semi-Annual Preventive Maintenance and Inspection

Requirements:

Semi-Annual service, when requested, will consist of the services listed in Quarterly as well as the following:

A. Cooling System

1. Analyze coolant for proper antifreeze percentage.

2. Analyze coolant conditioner level and add additional Supplemental Coolant Additive (SCA) as needed.

3. Tighten hose clamps as needed.

4. Lubricate fan drive with Caterpillar bearing lubricant for high speed applications and temperatures: minus thirty (-30)degrees Fahrenheit to three hundred twenty-five (325) degrees Fahrenheit.

5. Lubrication System

6. Check crankcase breather, inspect hose and connections.

7. Take oil sample for “Caterpillar Scheduled Oil Sampling Program” (S.O.S), or the appropriate prime mover program depending on the facility. Fuel

8. Clean primary fuel filter (if screen type).

9. Drain water and sediment from day tank (if accessible).

10. Clean Inlet filters for day tank.

11. Test day tank alarms.

B. Starting System

1. Test and record battery cells’ Electrolyte specific gravity.

2. Check and record battery voltage dip level during over crank test for minimum voltage required to maintain controls during start-up.

C. Air Intake System

1. Inspection of air cleaner seal for pliability and sealing.

2. Inspection of turbocharger for excessive end play clearance (if accessible) and seal leakage lubricate Governor Linkage.

D. Generator and Voltage Regulator

1. Check rotor air gap for correct clearance.

2. Inspection of rotor and stator for damage and excessive oil or dirt build-up.

3. Inspection of coupling and guards for loose or missing parts.

4. Check tightness of generator leads and voltage regulator control wiring.

5. Strap and tape any wiring or generator leads that have rubbing and /or worn insulation.

6. Inspect brushes and slip rings or rotating rectifier.

7. Clean and adjust voltage droop potentiometer.

8. Inspect exciter field.

9. Lubricate generator bearing with bearing lubricant for high-speed applications and temperatures minus ten (-10) degrees Fahrenheit to three hundred twenty-five (325) degrees Fahrenheit.

E. Control Panel

1. Check for and tighten loose terminals on the generator set and the generator control panel.

2. Check tightness of relays in the generator control panel.

3. Inspect for excessive dirt accumulation and clean as needed.

4. Test auto-start system.

5. Test safeties and pre-alarms on control and annunciator panels.

III. Annual Preventive Maintenance and Inspection Requirements:

Annual service, when requested, will consist of the services listed in Quarterly and Semi- Annual, as well as the following:

A. Change oil filters.

B. Change primary and secondary fuel filters.

C. Change engine oil (using oil meeting or exceeding manufacturer’s specifications, such as : API CH-4, CG-4, CF-4 or Natural Gas Oil if Sparked Ignited).

D. Legally dispose of waste oil and filters.

E. Replace inlet filter for day tank.

F. Load Bank Testing.

G. All additional tasks listed in the contract for annual checks.

H. After each visit, Contractor shall send a detailed follow-up report.