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