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

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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

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