Attachment VI - Maintenance Checklist Samples.pdf

CUMMINS GENERATORS MONTHLY MAINTENANCE

Cummins Generators MONTHLY GENERATOR MAINTENANCE LOG PAGE 1 OF 3

WORK TO BE PERFORMED O

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MONTHLY

HOURS OF OPERATION

BEFORE GENERATOR START-UP:

WALK AROUND INSPECTION

CHECK ALL BATTERY CONNECTIONS

CHECK ELECTROLYTE LEVELS

CHECK COOLANT LEVEL FOR OIL

RECORD ANTI-FREEZE STRENGTH

CHECK ALL FUEL LINES FOR LEAKS

CHECK & CLEAN DAY FUEL TANK

PUMPS & AREA

CHECK MSA FUEL SENSOR

RECORD FUEL READING ON FUEL

LOG (LOCATED BY GAUGE)

CHECK FOR H2O IN ALL FUEL TANKS

CHECK ENGINE OIL

CHECK ALL BELTS; REPAIR IF NEEDED

IF DIESEL TANK < 1/2 FULL NOTIFY COR

CLEAN DIRT & DUST FROM EXTERIOR

OF UNIT

CLEAN INTERIOR OF GENERATOR

SHELTER

BLOW-OUT GENERATOR WINDINGS

WHILE GENERATOR IS RUNNING

RECORD OIL PRESSURE (psi) RECORD FUEL PRESSURE (psi) RECORD FREQUENCY (rpm)

RECORD GENERATED VOLTAGE

RECORD CHARGING AMPERAGE

CHECK GOVERNOR OPERATION

INSPECT PARALELLING GEAR FOR

PROPER OPERATION ADJUST

SETTINGS AS NECESSARY

MANUALLY STICK UNDERGROUND FUEL

TANK AND RECORD READINGS ON LOG

CUMMINS GENERATOR QUARTERLY AND ANNUAL MAINTENANCE LOG

Cummins Generators QUARTERLY & ANNUAL GENERATOR MAINTENANCE LOG

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QUARTERLY (NOV, FEB, MAY,

AUG)

PERFORM MONTHLY

MAINTENANCE

REPLACE AIR FILTERS IF

NEEDED

CHECK CONTROL PANEL FOR

LOOSE

WIRING

CHECK INTAKE/EXHAUST

AREAS

CHECK HOLD DOWN BOLTS

YEARLY (MAY)

PERFORM MONTHLY &

QUARTERLY

BEFORE ENGINE START-UP:

CHECK COOLANT (ADD

CONDITIONER

IF NEEDED)

DRAIN WATER & SEDIMENT

FROM FUEL

TANK

CHANGE FUEL/WATER FILTERS

REPLACE ALL AIR FILTERS

INCLUDING DAY AND BELLY

TANKS

CHANGE ENGINE OIL & FILTER

TAKE OIL SAMPLE FOR

ANALYSIS

CLEAN/CHANGE CRANKCASE

BREATHERS

CHECK VALVE LASH, VALVE

BRIDGE &

INJECTOR TIMING

CHECK ADJUST & LUBRICATE

LINKAGES

LUBRICATE GENERATOR

BEARINGS

CHECK FAN FOR HUB BEARING

PLAY

CLEAN RADIATOR & FAN

ASSEMBLY

REPLACE BATTERIES EVERY 2

YEARS

2013, 2015, 2017, 2020, 2023

WHILE GENERATORS RUN:

PERFORM MONTHLY &

QUARTERLY

LOAD TEST OF AT LEAST 30%

FOR

MINIMUM OF 2 HOURS WITH

LOAD BANK

RECORD SERVICE METER

RECORD ENGINE JACKET

WATER

TEMPERATURE

RECORD EXHAUST

TEMPERATURE

MAKE ANY REPAIRS OR

ADJUSTMENTS AS

AFTER GENERATORS RUN:

CHECK OIL LEVEL

CHECK FOR LEAKS-WATER,

FUEL, OIL

CHECK TO INSURE STATUS IN

AUTO-START

MODE & BREAKERS SET

November and May take fuel samples of all tanks

CUMMINS GENERATORS 3-YEAR MAINTENANCE LOG

Cummins Generators THREE YEAR GENERATOR MAINTENANCE LOG PAGE 3 OF 3

WORK TO BE PERFORMED DURING

YEARLY MAINTENANCE EVERY THREE

YEARS IN MAY:

DRAIN & CLEAN COOLING SYSTEM

REPLACE THERMOSTATS, GASKETS &

SEALS

REFILL COOLING SYSTEM

REPLACE RUBBER BELTS & HOSES

REPLACE BATTERIES IF NEEDED

CHECK/INSPECT TURBOCHARGERS

SERVICE ENGINE

1250 KW BALDOR GENERATORS MONTHLY MAINTENANCE LOG

1250 KW BALDOR GENERATORS MONTHLY GENERATOR MAINTENANCE LOG PAGE 1

OF 3

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MONTHLY

RECORD HOURS OF OPERATION

BEFORE GENERATOR START-UP:

CONDUCT EXTERNAL INSPECTION (CHECK FOR LEAKAGE OF FUEL, OIL,

COOLANT)

CHECK FUEL LEVEL AND RECORD READINGS IN LOG. NOTIFY COR IF 1/2

TANK

OR BELOW.

CHECK ENGINE OIL LEVEL (CHECK FOR MIXING OF OIL AND WATER)

CHECK AIR COOLER FOR LEAKS

CHECK ALL BATTERY CONNECTIONS AND ELECTROLYTE LEVELS

RECORD ANTI-FREEZE STRENGTH (CHECK FOR OIL IN COOLANT)

INSPECT FUEL CONTROL LINKAGES AND BALL JOINTS

CLEAN FUEL FILTER (WIRE ELEMENT TYPE) TURN HANDLE ONE OR TWO

TIMES

CHECK BELTS FOR WEAR AND REPLACE AS NEEDED

CLEAN INTERIOR OF GENERATOR ENCLOSURE

BLOW OUT GENERATOR WINDINGS

CHECK ALL FUEL LINES FOR LEAKS

CHECK FUEL PUMPS FOR LEAKS AND TEST RUN FOR PROPER OPERATION

CHECK FOR WATER IN ALL FUEL TANKS

WHILE GENERATOR IS RUNNING FOR 1/2 HOUR UNDER LOAD

CHECK FOR EASE OF STARTING, COLOR OF EXHAUST SMOKE, ABNORMAL

VIBRATION, NOISE, SMELL, ETC., AND GAUGE INDICATION OF A PROBLEM

RECORD EXHAUST TEMPERATURE GAUGE, IF PRESENT

RECORD TACHOMETER

RECORD OIL PRESSURE (psi) RECORD FUEL PRESSURE (psi) RECORD FREQUENCY (rpm)

RECORD GENERATED VOLTAGE

RECORD CHARGING AMPERAGE

CHECK GOVERNOR OPERATION

RECORD OUTPUT POWER (KW)

CHECK FUEL INJECTION PUMP AND HYDRAULIC AND ELECTRONIC

GOVERNOR

RACK MOVEMENT

INSPECT PARALELLING GEAR FOR PROPER OPERATION; ADJUST AS

MANUALLY STICK ABOVEGROUND FUEL TANK AND RECORD READINGS IN

LOG

TANK AND RECORD READINGS ON LOG

1250 KW BALDOR GENERATOR MONTHLY MAINTENANCE LOG

1250 KW BALDOR GENERATORS SEMI-ANNUAL & ANNUAL GENERATOR MAINTENANCE LOG PAGE 2 OF 3

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SEMI-ANNUALLY (OCT, APR)

PERFORM MONTHLY MAINTENANCE

REPLACE AIR FILTERS IF NEEDED

CHECK CONTROL PANEL FOR LOOSE WIRING

CHECK INTAKE/EXHAUST AREAS

CHECK HOLD DOWN BOLTS

CHECK LLC CONCENTRATION IN THE COOLANT

CLEAN THE INSIDE OF THE COOLANT TANK

ANNUALLY (OCT)

PERFORM MONTHLY & SEMI-ANNUAL MAINTENANCE

INSPECT V BELT. ADJUST TENSION AS NEEDED. REPLACE

BELTS

AS NEEDED.

INSPECT AND TIGHTEN EXTERNAL NUTS, BOLTS.

INSPECT AND ADJUST VALVE CLEARANCE AND RELATED

PARTS

INSPECT VIBRATION ISOLATING RUBBER COMPONENTS

INSPECT FOUNDATION ANCHOR NUTS, BOLTS

INSPECT COUPLINGS. REPLACE COUPLINGS AS NEEDED

DRAIN WATER AND SEDIMENT FROM ALL FUEL TANKS

DRAIN WATER FROM WIRE ELEMENT-TYPE FUEL FILTERS

INSPECT AND ADJUST FUEL INJECTION NOZZLE SPRAY

CONDITION

AND SPRAY PRESSURE

INSPECT AND ADJUST FUEL INJECTION TIMING

PERFORM ENGINE OIL SAMPLING AND ANALYSIS

INSPECT AND ADJUST ENGINE OIL PRESSURE

INSPECT WATER PUMP

INSPECT AND CLEAN STRAINER FOR COOLANT

ANALYZE COOLANT PROPERTIES AND REPLACE AS

INSPECT AIR FILTER. REPLACE AIR FILTER AS NEEDED.

INSPECT STARTER(S)

INSPECT ALTERNATOR

CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

INSPECT AIR HEATER

CHECK FOR ANY LOOSE WIRES OR LOOSE CONNECTIONS

CHECK DEVICES FOR PROPER OPERATION: HIGH TEMP,

LOW OIL

PRESSURE, OVERSPEED, START FAILURE, WATER SUPPLY

FAILURE,

UNDERVOLTAGE, OVERVOLTAGE, OVERCURRENT, LOW

COOLANT

LEVEL, LOW FUEL LEVEL, ETC.

CHECK AUXILIARY DEVICES FOR PROPER OPERATION:

FUEL

CONTROL SOLENOIDS, FUEL SUPPLY PUMPS, UNIT

HEATERS,

WATER JACKET HEATERS, BATTERY CHARGERS, ETC.

AFTER GENERATORS RUN:

CHECK OIL LEVEL

CHECK FOR LEAKS-WATER, FUEL, OIL

CHECK TO INSURE STATUS IN AUTO-START MODE &

BREAKERS SET

RECORD SERVICE METER

MAKE ANY REPAIRS OR ADJUSTMENTS AS

TAKE FUEL SAMPLES OF ALL TANKS

IN NOVEMBER AND MAY

1250 KW BALDOR GENERATOR MONTHLY MAINTENANCE LOG

1250 KW BALDOR GENERATORS TWO-YEAR AND FOUR-YEAR GENERATOR MAINTENANCE LOG

WORK TO BE PERFORMED DURING TWO-YEAR MAINTENANCE:

PERFORM MONTHLY, SEMI-ANNUAL, AND ANNUAL

MAINTENANCE (OCT)

CHANGE ENGINE OIL, OIL FILTERS, AND BYPASS OIL

SAMPLE AND ANALYZE ENGINE OIL PROPERTIES

CLEAN WIRE ELEMENT FUEL FILTERS

CHANGE NON-WIRE ELEMENT FUEL FILTERS

DRAIN & CLEAN COOLING SYSTEM

REPLACE THERMOSTATS, GASKETS, AND SEALS

REFILL COOLING SYSTEM

REPLACE RUBBER BELTS & HOSES

REPLACE BATTERIES

CHECK/INSPECT TURBOCHARGERS

WORK TO BE PERFORMED DURING FOUR-YEAR MAINTENANCE:

PERFORM MONTHLY, SEMI-ANNUAL, ANNUAL, AND TWO-YEAR

MAINTENANCE (OCT)

CHECK OIL COOLER FOR SOILING, CLOGGING, AND LEAKAGE

CHECK OIL PUMP FOR DISCOLORATION AND OTHER EXTERNAL

DEFECTS

INSPECT AND TEST GOVERNOR. REPAIR AS NEEDED.

INSPECT AND CLEAN FUEL TANK

INSPECT AND TEST FUEL INJECTION PUMP. REPAIR AS NEEDED.

REPLACE RUBBER HOSES.

INSPECT AND CLEAN AIR CLEANER ELEMENT

INSPECT AND CLEAN PRE-CLEANER

INSPECT ALL GAUGES. REPAIR AS NEEDED