J061--Requirement- Preventive Maintenance Caterpillar Facility Backup Generator Services

Generator PM Check List

1. Visually Inspect Radiator/Heat Exchanger for Leaks, Damage and Obstruction

2. Add coolant to Bring the Coolant to it' s Correct Level (Max 2 Gals)

3. Inspect Condition of Radiator Cap. Gasket and Sealing Surface

4. Analyze Coolant for Proper antifreeze Percentage - -30

5. Analyze Conditioner SCA Level and add Additional SCA as Needed - 2000

6. Visually Inspect Water Pump and Cooling System Gaskets for Leaks

7. Inspect Flexible Water Connections for Cracking, Leaks and Pliability

8. Re-Torque Hose Clamps

9. Inspect Pulleys for Excessive Wear

10. Inspect Belts for Cracking and Fraying

11. Check Belt Tension

12. Check Jacket Water Heater(s) for Proper Operation and Adjust Thermostat Setting

13. Add Crankcase Oil to Bring the Oil to its Correct Level (Max 2 Gals) (Change Oil and Filters for Annual PM)

14. Inspect Oil Heater for Proper Operation and Check Thermostat Sea ls

15. Visually Inspect Front and Rear of Crankshaft Seals and Lubrication System Gaskets for Leaks

16. Record Fuel Level in Main Fuel Tank

17. Stick Main Tank for Water - 0

18. Test Day Tank Pump for Proper Operation and Level

19. Test Day Tank Alarms

20. Drain Water and Sediment from Day Tank (if accessible)

21. Clean or Replace In let Filters (during annual PM only) for Day Tank

22. Clean Primary Fuel Filter (if screen type)

23. Drain Water from Water Separator

24. Operate Fuel Priming Pump and Check for Proper Operation and Leaks

25. Check the Engine' s Fuel System for Leaks

26. Inspect Flexible Fuel Lines for Cracking, Leaks and Pliability

27. Check Governor Oil Level and Add Oil as Needed

28. Inspect Steel Fuel Lines for Cracks, Leaks and Proper Line Bracket Support

29. Check and Record Battery Cells Electrolyte Specific Gravity

30. Top Off Electrolyte Level

31. Check and Record Battery Charger Amperage a. Equ.. Rate: - 8.5

b. Float Rate: - 5.0

32. Check Battery Charger and Adjust Float Rate for Optimum Battery Performance and Life: a. Equ. Volts: - 29.6

b. Float Volts: - 28.4

33. Tighten Battery Cable Connections as Needed

34. Clean and Apply Corrosion Inhibitor to Terminals of Only Lead Acid Batteries as Needed

35. Inspect and Tighten Starter Motor Connections and Wiring

36. Inspect Flexible Exhaust Coupling for Cracks and Excessive Leakage

37. Visually Inspect Exterior of Exhaust Manifolds for Oil or Fuel Slobbering (signs of wet stacking)

38. Inspect Exhaust Rain Protection and/or Exhaust Outlet Screening

39. Drain Water in Exhaust Moisture Traps

40. Inspect Exhaust Manifold(s) for Broken or Missing Hardware

41. Inspect Air Filters for Plugging and Deterioration

42. Test Air Cleaner Indicator

43. Check All Air Intake Piping for Damage and Loose Connections

44. Inspect Turbocharger for Seal Leakage and Excessive End Play Clearance (if accessible)

45. Perform an Operational Check of Illumination and Safety Lamps

46. Check for and Tighten Loose Terminals on the Generator Set and Generator Control Panel

47. Check Tightness of Relays in the Generator Control Panel

48. Inspect for Excessive Dirt Accumulation in the Control Panel and Clean as Needed

49. Inspect air Cleaner Seal for Pliability and Sealing

50. Check Rotor Air Gap for Correct Clearances

51. Inspect rotor and Stator for Damage and Excessive Oil and/or Dirt build Up

52. Inspect Coupling and Guards for Loose or Missing Pa11s

53. Check Tightness of Generator Leads and Voltage Regulator Control wiring

54. Strap and Tape any Wiring or Generator Leads that Have rubbing or Worn Insulation

55. Inspect Brushes and Slip Rings or Rotating Rectifiers

56. Clean and Adjust Voltage Droop Potentiometer

57. Clean Crankcase Breather, Inspect Hose and Connections

58. Lubricate Fan Drive with Caterpillar Bearing Lubricant (annual PM only)

59. Lubricate Governor Linkage with Caterpillar Bearing Lubricant (annual PM only)

60. Lubricate Generator Bearing with Caterpillar Bearing Lubricant (annual PM only)

61. Inspect Generator Set Vibration Isolators and Adjust as Needed

62. Make a Walk Around Inspection of Complete Installation

63. Check for Unit On-Line Capability in Less Than Ten Seconds

64. Check and Record Battery Voltage Dip Level During Over crank Test for Minimum Voltage Required to Maintain Controls During Starting - 22.1

65. Check for Proper Cranking Termination Upon Starting

66. Check Proper Operation of Engine and Generator Instruments with Generator Running

67. Adjust Governor Control for Optimum Performance and Frequency - 60.0

68. Adjust Voltage Regulator for Proper Voltage - 482

69. Record Field Voltage During Generator No-Load Run for Base Line '0. Check and Record Alternator Voltage with Engine Running

70. Check for Abnormal Noise or Vibration

71. Check for Abnormal Exhaust Characteristics with Engine Running (signs of wet stacking)

72. Check for Proper Operation of Remote Fan Motors, Thermostats, Circulating Pumps, and Solenoid Valves

73. Check Inlet and Discharge Louvers for Proper Operation with Engine Running and Stopped

74. Check for Excessive Crankcase Blow-by with Engine Running

75. Re-Check Oil Level with Engine Running

76. Re-Check for Leaks with Engine Running

77. Test Auto-Sta rt System

78. Test Safeties and Prealarms on Control and Annunciator Pane ls

79. Take Oil Sample (after operational checks) for Caterpillar S.O.S. Program

80. Rest All Controls to Auto ma tic

81. Set Circuit Breaker to Correct Position

82. Check Fuel Valves for Correct Position

83. Check Voltage Regula tor is ON and NOT Tripped

84. Check Battery Charger is ON

85. Check Day Tank Controls are ON

86. Check Remote Radiator Fan Controls are ON

87. Check Auxiliary Water Pump Controls are ON

88. Check Jacket Wate r Heater(s) are ON

89. Check Louver Controls are ON